PREFACE. Courtesy HondaéFun ‘This Shop Manual details the proper servicing and repairing procedures for mechanics working on the HONDA 500, Model CB500. Carefully reading the complete section before beginning the work and following the steps in the order given will result in better maintenance and repair with less trouble and time consumed. Always keep the recommended special tools at the work bench when performing repairs Use only genuine HONDA replacement parts. Service data for individual parts is consolidated into a single section at the rear of the text, for quick reference. ‘The descriptions and specifications in this manual are those in effect at the time this manual was approved for printing. ‘This manual is a courtesy of Honda4Fun (www.hondadfun.com - www.hondafour.com). HONDA MOTOR CO., LTD.HONDA CBS00FQUR CONTENTS [ =| CHASSIS AL TOOLS i Front wheel and front brake z o be) Ry Cy = ES REPAIR PROCEDURE ! | U9, XY, OPERATIONS Rear wheel and rear brake Steering 5 a Zz a Servicing with engine Rouites cians Front suspension Rear suspension [= | i Engine removal and installation Cylinder head, cylinder and piston Frame body ELECTRICAL, TI, Ss Valves and valve springs General description a | Oil pump and oil filter Clutch GOOG PY Ignition system v fa Gear shift mechanism Charging system Cam chain tensioner Bec OUy Starting system Crankshaft and connecting rod Electrical equipments Dy, ie I nsmission, kick starter and primary shaft 4 TROUBLE SHOOTING PERIODICAL MAINTENANCE a TECHNICAL DATA Carburetor Ea yy 2 5 Zz g g 2 A, INDEXCourtesy of )HondagFun REPAIR PROCEDURE | i 1. When performing an overhaul, all the disassembled parts should be separated in their respective groups so that they will not become mixed. 2, Replace all packings, gaskets and cotter pins with new items when reassembling. Always replace any deformed snap rings with new items. 3. Clean all engine parts after disassembly. Coat friction surfaces of metal parts and bearings with oil, 4. When repairing or replacing the parts, use the recommended special tools for better results. Torque all nuts, bolts and screws, starting with those of large diameter, and from inside to outside symmetrically. 6. Refer to torque values shown in the following table. ENGINE Torque values Item ay = 1.) Tappet adjusting nut 10.8 2 | Cam sprocket knock bolt, 7312 11,5145 % Cylinder head nut, 8mm 1 14.5-16.6 4 A.C. generator rotor set bolt 28.9-30.3 5, Starting clutch serew, 8:20 cross flat head screw 14,517.3 6 Upper erankease bolt, 8100 hex bolt 16.6-18.0 7. Upper crankcase bolt, 8125 hex bolt 16.6-18.0 8% Lower erankease bolt, 8100 hex bolt 1 16,6-18.0 8. Connecting rod nut 14.5-15.8 10. | Oil pump screw, 635 cross flat head screw 57-86 11, | Cluteh filter fixing bolt, 6x45 hex bolt 57-86 12. | Spark advancer bolt, 6%55 hex bolt 57-86 13. | Tachometer gear holder screw, 6%16 cross flat head screw 7.24101 14. | Exhaust pipe flange nut, 6mm 57-86 15. Oil pressure switch 10,8-14.5 16. | Gear shift lever bolt, 620 hex bolt 57-12 17. | Oil filter center bolt 19,5-28.8 86-11.6 18 | Spark plug 19. | Oil drain bolt 20. | Clutch spring, 6% 20 hex bolt 21, | Exhaust flange, 6mm nut 22 Oil Biter center bolt 23. | Tappet hole cap 24. | Oil path cap 25. | Gear shift return spring, 8mm bolt Standard paris Bolt hex. 6mm “0.81.2 57-86 Bolt hex. &mm 2024 14.5-17.3 Screw cross, 6mm 0.81.2 57-86eieees CHASSIS hen ow Torque values = fi-lbe 1. Rear brake pedal bot, 8:32 hex hole 1) e268 | 108i 2 | Step bar out. 12mm 2 5060 | 352434 3. Engine hanger bolt A 5 | 1040 | 21.7280 4. Engine hanger plate 6 | .e25 © 1s01a1 5 | Rear fork pivot mut, Mmm 1 | 5570 © s.e506 6 Rear suspension upper nut, 10mm cap aut 2 4040 © 2,7-289 7. Rear suspension lower bolt, 10x32 hex bolt 2 a040 27-289 Front brake & | Oil bo 2 | 2440 | 26280 8 Brake stop switch 1 adeo | 6289 10. Front brake dise nut, 8mm 6 1829 | 120166 11, Brake oil joint, 628 hen bolt 1) geno | se72 12, Brake hose joint 1 | o610 | 497. 13, Master eylinder bolt, 6% 28 hex bolt 2 08.0 | Br72 14. Caliper set bole 2 3440 | 26280 15, Holder joint bolt, 8:40, 650 hex bolt 3 Lees | 130-186 | 16. | Front fore bote 2 | S665 w.e470 11, | Steering stem nut 1 0120 57.9-86.7 18, Steering stem bolt, 10:40 hex bolt 2 | 4040 | 2.7280 18. | Rear wheel axle nut 1 | 0100) sr.e723 2%, Front axle holder nut, 8mm 4 L823 13. 0-16.6 21. | Handlebar holder bolt, 8:40 hex bot 4 1829 180186 22. | Front wheel axle nut 1 5.565 39. 8-47.0 23. Rear brake stopper arm bolt and nut, 8mm T 1823 13, 0-16.6. 24, | Fork top bridge bolt, 856 hex bolt 2 | 1823 | 180186 25, | Drive chain adjuster bolt and nut, 8mm hex bolt 2 | 4520 | 1816s 26, Drive chain adjuster stopper bolt 2 | 1e2a | 130-166 27. | Main stand pivot pipe bolt, 840 hex bolt 2 1.5-2.0 10.8-14.5 2m 2 | 4560 asan4 29. | Caliper joint pin 1) 125 | 10-81 30. | Bottom bridge 2 | 3040 | 217-280 31. Finaldriven sprocket 4 30-40. 21.7-28.9 ‘Standard parts \- Bolt hex. 6mm Bolt hex. mm 1523 10.8166 |somes Courtesy SPECIAL TOOLS) “""" HondaaFun a) 07000: 07001-32301 07003-82301 07004-82301 07007-82301 07008-32301 07046-32301 07081-30011 07031-32301 07032-32301 07033-55101 07001-32301 07997-05101 Deaipoon Special Tool Set for CB 500 Valve seat 90° cutter Inlet valve seat top cutter Exhaust valve seat top cutter Talet valve seat interior cutter Exhaust valve seat interior cutter Valve seat cutter holder Valve guide reamer Valve guide driving and removing tool Valve spring compressor Valve spring compressor attachment Piston ring compressor (2 pes) Piston base (2 pes) Valve seat cutter set Valve seat cutter caseCourtesy HondaaFun 4 Hfour.com rorehondedfuncore 9 SPECIAL TOOLS | © << ® » — ® a ® @ [Rat Ne Teal Na —Tesspeen = a 07081-32301 Valve tappet lock nut wrench 8 07087-32301 Carburetor synchronization adjusting wrench @ 07078-32301 igsum cylinder heed nat wrench ® 07094-32301 Spark plug wrench a 07011-21601 AC generator rotor puller @ 07009-32301 Sliding hammer shaft (primary shaft remover) @ 07009-32305 Sliding weight a 07073-32301 Master cylinder sip cing plies a 07043-32301 Fistoe. exp auras @ 07072-20001 48mm steering stem top thread wrench 07085-32301 6mm fork bottom case bolt wrench 07043-32305 Master cylinder piston guideHondaaFun 3, Tool No. Description Bearing retainer wrench A (front 07088-32905 Bearing retainer wrench B (rear 07034-32301, Front fork assembling bar 07035-30001 Rear cushion disassembling and assembling. tool 07048-32301 Bearing driver A (07048-32320 Be (07048-32305 4 07048-22315, Bearing driver attachment B 07068-20007 Vacuum gauge attachment (A) (2 pes) 07068-30010 Vacuum gauge attachment (B) (2 pes: 07064-30012 Vacuum gauge (1 pes) (07064-30001 Vacuum gauge set 0790-29201 Tool case 07065-30001 Pressure gauge | | | @G288882998) 4 (07068-30001 Oil pressure gauge1, TAPPET ADJUSTMENT ‘Adjust tappet clearance when the engine is cold, 1. Remove the tank. 2, Unscrew the tappet hole caps. 3. Remove the point cover and align the “'T” (1-4) mark on the spark advancer to the timing mark when the No. 1 piston (pistons are numbered from left to right from the rider’s position) is at top-dead- center of the compression stroke. 4. Then check and adjust valve tappet clearances indicated by “‘O” in the chart below. 5. Measure the clearances using a feeler gauge, adjust by loosening the lock nut and turning the adjuster screw, and tighten the lock nut. Valve tappet clearances INLET 0.05 mm (0,002 in.) EXHAUST —0. 08 mm (0. 003 in.) 6. Next, rotate the crankshaft one revolu- tion and realign the “T” (1+4) mark on the spark advancer to the timing mark (in this position, the No. 4 piston is "pig. 2 cy T mark at top-dead-center of the compression @) Timing mark stroke). Then check and adjust the valve tappet clearances indicated by “X" in the chart below. See item 5 above for proper valve tappet clearances Fig. 1 @ No.1 piston @ No. 3 piston @) No. 2 piston —@ No. 4 piston @ 1-4 mark cylinder cylinder] ee fe leks + Hold the adjusting screw so that it is not turned when tightening the lock nut. + Make sure the clearance is not disturbed when the lock nut is tightened. D Adjusting screwCourtesy HondadFun 8 3, MAINTENANCE OPERATIONS wew.hondatour.com( /whondattin.com 2. CARBURETOR ADJUSTMENT Adjust the carburetor after warming up the engine (60-70°C/140-158°F Temp). Idle adjustment Adjust the engine idle speed to 950-1050 rpm with the throttle stop screw. Turn the screw clockwise to increase the idle speed and counterclockwise to decrease the idle speed. Synchronization adjustment 1. Remove the fuel tank. Note: Fig. 4 @ Throttle stop screw Position the tank about than the mounting. pos with a longer fuel tube. 2, Adjust the throttle stop screw so that the throttle lever is 49-1. 5mm ( Yiein.) from the stay. 3, Install the vacuum gauge in the inlet manifolds. Remove the plugs from the inlet. manifolds. Install the longer A adaptors of the vacuum gauge to the two inside manifolds and the shorter B adaptors to the outside manifolds 4. Start the engine, loosen the adjusting lock nuts and turn the adjusting screws so that all four carburetors are indicating jem (20in,) higher m and reconnect, TE De ee ie uniformly (16-24em Hg) on the vacuum @ Stay gauge Turn the screw clockwise to decrease vacuum pressure. Turn the screw coun- terclockwise to increase vacuum pressure. All the carburetors should be adjusted thin 3.0em Hg of each other. to Note If the gauge needle is oscillating over a wide range, dampen the movement with the vacuum adjuster on the gauge. @ Vacuum gauge @ Plug holeCourtesy of HondaaFun sree nondetourcom( /Wawhondedtincom 3. MAINTENANCE OPERATIONS ° Snap the throttle several times and recheck vacuum pressures after the four car buretors are indicating the same vacuum pressure, Repeat the adjustment in item 4 if vacu- um pressures lack uniformity. Check the following items if vacuum pressure is less than 15em Hg for any of the carburetor 1. Be sure the ignition timing is —5°/1,150—30°/2,500 rpm BTDC. 2. Check the tappet clearances. Inlet: 0.05mm (0. 002in. Exhaust: 0.08mm (0.003 3. Check the spark plug gap. Gap: 0.6-0.7mm (0,024-0. 028in.) 4. Check the compression pressure Pressure: 11-12 kg/em® (156. 45-170. 67 psi.) 6. Adjust the throttle stop screw to an engine @ ® idle speed of 950~1,050rpm after all four carburetors have been adjusted to 3 @ lew am @ High veo the same vacuum pressure Adjust the air screw on each carburetor. the standard adjustment for the air crews is 1+3/8 turn open from the complete close position) 8, Readjust the engine idle 1,050rpm with the thrott ote: hten the plugs in the inlet manifold after performing the carburetor synchro- 2 Normal ed to 950 stop screw a Throttle Cable Adjustment C @ 1, Turn the adjuster counterclockwise at Fig. 9 @) Adjuster @ Lock nut the handle bar end to increase play in the throttle cable. Note: Leave about 3mm (0.12in) range of adjust. ment at the cable adjuster for final micro- adjustment. Loosen the cable lock nut and turn the adjuster at the carburetor end to provide 3~4:mm ("/s~"/ein,) play at the throttle grip flange. Note: The throttle lever should hit the eccentric pin when the grip is forced to the full Slosed position. Replace the return cable Fig. 10 (Adjuster = cane with new one if it does not hit. ® Lock nut @ IncreaseME ire a Overtravel stopper adjustment ) _@ Loosen the lock nut and turn the eccentric pin. Clearance between the throttle lever and the eccentric pin should be 2~3mm (0. 08~0. 12 in) 10 3 Fig. 11 @ Throttle lever @ Lock nut 3 mim (0. 08~0. 12 in, Full throttle opening stopper adjustment Adjust the stop screw so that the throttle valve extends 0~1. 0mm (0~9. 04 in.) above the throttle bore in the full open position. Fig. 12) Stop screw 3. BREAKER POINT GAP AND IGNI- TION TIMING ADJUSTMENT Check the condition of the contact points, point gap and ignition timing. Adjust the ignition timing of the 1-4 points first. Breaker point gap adjustment, 1-4 points 1. Rotate the crankshaft until the slipper on the contact breaker is coming up on the highest position of the cam lobe. Measure the point gap with a feeler gauge Standard point gap: 0.3~0.4mm (0.012~ 0.016 in.) Loosen serew @ and move the breaker point assembly if it is necessary to adjust. Breaker point gap adjustment, 2-3 points Adjust the 2-3 point gap in the same manner as for 1+4 points by loosening screw i Note: Clean the point surfaces with a point file or oil stone if they are pitted or rough. Fig. (Screw @) @) Breaker @ 2-3 points ® Screw ® @1-4 pointeCourtesy HondadFun Grhenteloursem /Wieaenaethmcem % MAINTENANCE OPERATIONS un Ignition timing adjustment, 1-4 points 1. Disconnect the primary cord (blue cord) to the contact breaker at the connector and connect a 12V test lamp at this point. Turn the main switch to the ON position Rotate the crankshaft slowly. If the test lamp comes on when the “ F” (1-4) mark on the spark advancer is aligned to the timing mark (5° BTDC), the timing is correct. 4. If the adjustment is necessary, align the F” (1-4) mark to the timing mark and loosen screw ‘, and then move the base B until the lamp goes out. Tighten the screw Ignition timing adjustment, 2-3 points 1. Connect the 12V test lamp to the pri mary cord (yellow cord) of the opposite contact breaker and align the mark to the timing mark. 2. Loosen screw @ and move base © as shown above. Ignition timing adjustment with strobo- scopic timing light The use of the stroboscopic timing light is recommended to obtain the most accurate timing. 1. Plug the timing light cord into the timing light receptacle. 2 Remove the spark plug cap from the No. 1 cylinder and install the timing attachment between the spark plug and the cap, 3. Connect the high tension cord of the timing light to the timing attachment, position the switch knob to TIMING, and start the engine. The timing light will be flashing. 4. Aim the timing light toward the timing mark and make sure the “F” (14) mark and the timing mark are in line Next, increase the engine rpm at approx. 2500 rpm and at this speed, if the timing mark is between the two index lines located 29.5~26.5° before “F” mark, the ignition timing at full advance condition is satisfactory. DV lamp @ Blue cord D Timing Hight @ Battery 2 Timing attachment “5 Service tester 3 Switch knob12 Fig. 19 { D Lock bolt @ Adjuster D Increase free play © Decrease free play 5. ® 1 2, 3 D Lock nut 2) Adjuster Fig. 22 @) Increase free play @ Decrease free play & MAINTENANCE OPERATIONS www. Courtesy of Next, remove the spark plug cap from the No. 2 cylinder and install the timing attachment between the spark plug and the cap. Check the ignition timing (“F” 2-3) as described items 1~4. Adjust if timing is incorrect. CLUTCH ADJUSTMENT To provide play in the clutch cable, loosen the clutch adjuster lock bolt. Turn the adjuster clockwise until a slight resistance is felt, and then turn counter- clockwise about 3mm ('/sin.). At that point, tighten the lock bolt Adjust play in the clutch cable at the lock nut and adjuster. The play should be 10~20mm (0.4~0.8in.) micro adjustment with the adjuster at the clutch lever end. Perform CAM CHAIN ADJUSTMENTS Perform eamehain tention adjustment in the following manner Remove the tappet hole caps from the No. 1 cylinder. Remove the point cover, and align the “T" (1-4) mark to the timing mark Check both valves of No. 1 cylinder. If both valves are free, proceed to next step; if either or both of the valves are HondadFunight, rotate the crankshaft 360°, and then proceed with the next step. Rotate the crankshaft clockwise until the pel the 1-4 position is just to the right of a line from the timing This sition is 15° ATDC At this point, loosen the lock nut so that proper chain tension can be obtained on the advancer assembly at mark. automatically. Retighten the lock nut point cover and tappet covers. 6. SPARK PLUG INSPECTION with a spark plug gap and the insulator \d_ re-install ve the spark ph ch and check damage or fouli Clean the ner or a wire brush 2 Check the gap with a feeler gauge and adjust the opening to the standard 0.6~ 7mm (0.02~0.03 in). Replace the plug or plug gasket if the lator or gasket is damaged Standard spark plugs: D-7ES (NGK) X22ES (DENSO) ENGINE OIL INSPECTION AND CHANGE Oil Level Inspection Check the oil level with the dipstick gauge ithout serewing it into the case. If the level is below the lower mark on the gauge, add oil to the upper mark. Recommended oil classification SAE 10W-40 or SAE 20W-50 Oil change orm the oil change while the engine is arm so that oil will drain properly. Unscrew the drain bolt, and also remove with @ spark plug clea the filler cap to assist draining 2 Remove the oil filter to drain the oil completely Tighten the drain bolt and fill with 2.52 2.6U.S.qt., 2.2Imp.qt.) of new oil through the filler opening, Add oil as necessary to bring the oil level to the upper mark on the gauge. Oil capacity: 3.0 liters (3.2 2.6 Imp. at. 3, MAINTENANCE OPERATIO 1 Nut @ Adjusting screw Fig. 23 3 Timing mark © Spring peg 0.6~0.7 mam (0.02~0.03 in.)14 9, MAINTENANCE OPERATIONS Fig. 28 (Oil filter cover @ Washer 2) O rit § Oil filter element & Spring?" ~ @ Oil filter center bolt 5 8 i" per adjusting. balt 3B ® D Level line Fig. 30 8. OIL FILTER SERVICING Service the oil filter when changing the engine oil 1. Unserew the oil filter center bolt and remove the filter element. Note: - Certain amount of oil will drip from the filter when it is removed. + When reinstalling the element, make sure that no parts are forgotten or pieces of rubber left on the seat to cause poor sealing. «Replace the oil filter element with new item every 4,000 miles (6,000 km). 9. BRAKE INSPECTION AND ADJUSTMENT Caliper Return Travel Adjustment 1. Loosen the nut and turn the caliper adjusting bolt counterclockwise until the pad B lightly contacts the brake disc. (To decrease clearance, the adjusting bolt is turned clockwise bike, or counterclockwise from left side f bike. 2, Turn the 13 0 1/2 turn from this point and tighten the lock from right side of bolt clockwise nut, the front wheel off the ground and spin the wheel by hand to check for brake drag. Slight drag is acceptable. Brake Fluid Level Inspection 1, Remove the cap on the master cylinder and make sure that the fluid is up to the level line on the reservoir 2, Add brake fluid if the level is low or change the fluid if excessively dirty Recommended brake fluid SAE J1703a BRAKE FLUID Note: +Do not mix different brands of brake fluid as chemical action will take place and may cause brake trouble. +Do not use any other fluid in the brake system, of HondadFunHondaaFun Courtesy + Remove any brake fluid which may become spilled on the painted surface, rubber parts, and meter as it will produce chemical action and cause damage to these parts. Brake Pad Inspection Replace both pads A and B with new one when either of the pads is worn to the red serviceable limit mark aroung the pad Brake Bleeding Bleed brakes to remove the air from the brake system when the brake lever action feels spongy. 1. Fill the reservoir of the master cylinder with brake fluid to the height of the level line. 2 Connect a hose to the bleeder on the caliper and prepare a vessel to catch the fluid. 3. Pump the brake lever several time until pressure can be felt. With the brake lever held against the pressure, open the bleeder about half a turn, and when the lever bottoms against the handle bar, immediately close the bleeder, Repeat this operation several times until air bubbles no longer flow out with the fluid from the bleeder hose. Note: The fluid in the reservoir must be repleni- shed and not be allowed to become exhau- sted during the bleeding operation. +The reservoir must be capped when pumping the brake lever. Rear Brake Adjustment 1. Normal play at the end of the brake pedal is 2-3 em C/~lI3/s6 .. MAINTENANCE OPERATIONS 15 c o5mm (Gas Fig. 81 @ Red line Fig. 32 @ Brake fluid reservoir @ Brake lever Fig. 38 @ Caliper @) Bleeder hose ®) Bleeder @ Vessel Pig. 34Courtesy HondadFun 16 MAINTENANCE OPERATIONS swwhendafourcam( (itr hondedf uncom Perform the adjustment with the adjuster nut, 10, AIR CLEANER ELEMENT SERVICIN 1. Open the seat and remove the tool tray 2 Pull out the spring clip and take ier element the element by tapping it lightly and blowing compressed air from inside 11, DRIVE CHAIN INSPECTION AND ADJUSTMENT 1, Check the slack in th and lowering the chain at the midpoint between the sprockets. The normal slack is 1~2em (*/~*/s in), Adjust by Ic ig the rear axle nut and turning the adjust bolts on both sid hain by raising Note: ‘The marks on both adjusters should be at the same location when the chain is pro- perly adjusted. 2. BATTERY ELECTROLYTE INSPECTION Remove the right side cover and check the electrolyte level. The level should be at the upper limit 1. If the le remove the tool tray to add distilled water to the battery 2 Remove six battery filler caps and fill the water to each cell up to the upper 1 is low, open the seat and @ Lower limit limit3. MAINTE FRONT FORK OIL REPLACEMENT 1. Remove the fork holt and drain bolt, and then drain the oil Actuate up and down the fork to drain the oil completely 2, Flush the interior with the solvent Note: Do not use gasoline for flushing. 3. Tighten the drain bolt securely and add new oil to the fork of fork pipe. Recommended oil Capacity: 160.ce through the top SAE 10W~30 5, 4 ozs) 14. COMPRESSION PRESSURE CHECK 1, Remove the spark plugs Insert the end of the compression gauge into the spark plug hole. 3, Set both the throttle and choke to full open position and kick the kick starter. Standard compress n pressure 12 kg/m? (170. 67 psi) Note: + Fully open the throttle and choke so that the true compression pressure will be in- dicated on the gauge. Continue the kicking until the compression reading is at maximum because the reading inerease with each kicking. «To obtain the true pressure reading, per- form the measurement after warming up the engine. Low compression pressure When the compression pressure is below 10 kg/cm? (142,23 psi), the probab ks around the valves and piston rin, causes are from the head and cylinder gaskets Adjust the valve tappet clearances, or disas. semble the engine and inspect the piston rings and gaskets h compression pressure hen the pressure is greater than 12 kg/em’ 7 psi), the probable cause is excessive carbon deposits on the combustion chamber, piston head and the valves, Disassemble the head and cylinder, to remove the carbon. OPERATIONS 7 Fig. 40. () Fork: bolts Pig. AG) Drain bolt Fig. 42 @ Compression gauge Courtesy HondadFun| 4. ENGINEHonda4Fun detour com jodethancom 4, ENGINE 1. SERVICING WITH ENGINE MOUNTED IN FRAME Items Pages 1, Cylinder Head Cover and Camshaft 24 2, Cylinder Head 3, Cylinder and Piston 4, Cam Chain Tensioner 5. Oil Filter and Oil Pump 36 6. Clutch 40 7. Gear Shift Mechanism 43 8 Electrical System i.e., (Generator and Starting motor 95 2. ENGINE REMOVAL AND INSTAL- LATION A. Removal 1. Turn the fuel cock to the STOP™ posi- tion, disconnect the fuel pipe at the tank, # and dismount the foel tank, ——— 2, Unscrew the oil drain bolt and the oil [== filter center bolt, and drain the engine = oil = 3, Remove the exhaust pipe and the mufler, =a 4, Disconnect the high tension cords at the Ld spark plugs. 5, Disconnect the ground cable at the battery terminal. 6. Unscrew the 5mm screw and disconnect the tachometer cable at the cylinder head cover. Fig. 43 @ Drain bolt @ Oil iter center tot 7. Open the seat, take out the air cleaner element, unscrew three 6mm. bolts and remove the air cleaner case. er ig. 43 Fig. 44 Tachometer cable @ Smm screw Fig. 45.) Air cleaner element 3) Air cleaner 2 6mm bolts caseCourtesy HondaaFun 4, ENGINE wwrwhondstourcom( /Wawhondatn.com 27 8. Disconnect the throttle cable at the car: buretor. 9, Loosen the two 5mm screws at the carburetor insulator and the 4mm screws at the air cleaner chamber. Remove the carburetor. Fig. 47 () Smm screw @ 4mm screw 10, Disconnect the starting motor cable from the magnetic switch, and then the gener. ator wiring at the coupler. Fig. 48 ( Starting motor cable Wiring 2) Magnetic switeh coupler 11. Remove the gear change pedal, unscrew the starting motor cover bolts, remove the starting motor cover, and then remove the left crankcase cover, Disconnect the clutch cable at the clutch lifter. 49 @ Left crankcase cover) Cluteh lift @ Clutch cableHondaaFun Fig. 50 @ Contact breaker point leads 3) Fig. 51 Left side engine hanger bolts 8250 hex bolt 10>50 hex bolt Rear upper hanger bolt 40°80 hex bolt Rear lower hanger bolt D 8% 50 hex bolt 50 hex » Rear upper © 8% 100 hex bolt ©) 840 hex bolt @ Rear lower hanger bolt D 10%80 hex bolt ENGINE 12, Remove the final driven sprocket and the drive chain. 13. Disconnect the contact breaker point leads (yellow and blue) at the connectors. 14, Unscrew the ts from the engine han. ger bolts, and dismount the engine from the right side by raising it's rear slightly.4. ENGINE B, Engine Installation 1. Remount the engine in the reverse order of dismounting, however, attention should be given to the following points + Install the engine from the right side and tighten the hanger bolts. The bat- tery ground cable terminal is install together with the rear hanger bolt. + Make sure that the generator cord and starting motor cord are not pinched when the left crankcase cover is installed + Make sure that the two mufflers on each side are properly connected with the muffler connecting band. + Perform the following adjustments after the engine is installed. Cluteh adjustment Drive chain slack adjustment Carburetor adjustment so . 23 Fig. 5t D Generator cord 2) Starting motor cord24 Courtesy of HondagFun nthentefoureene /Gimaencetimen 4 ENGINE 3. CYLINDER HEAD, CYLINDER AND PISTON A. Disassembly 1, Turn the fuel cock to the “STOP” posi tion, disconnect the fuel lines at the tank, and dismount the fuel tank. 2, Remove the exhaust pipe and mufiler. 3. Disconnect the tachometer cable. 1. Disconnect the high tension cords at the spark plugs, unscrew six 6mm screws and remove the breather cover. Remove the tappet hole caps, left and right side covers, unscrew twelve 6mm screws and six bolts, and remove the cylinder head cover. Note: + Loosen the screws and bolts uniformly to relieve the stress gradually. Fig. 56 @ Breather cover Fig. 87) Cylinder head cover 2) 6mm copper washers 6, Loosen the lock nut of the cam chain tension adjuster (leave the wrench on the nut), turn the screw fully (approxi- mately 90°) clockwise, and then tighten the lock nut In this condition the cam chain ten- sioner is not applying tension to the cam chain. Fig. 88 (1) Cam chain tension adjuster ® Lock ‘nut 7. Unserew two cam sprocket mounting bolts and remove the camshaft from the sprocket. 8. Remove the cam chain from the sprocket. Fig. 59 Cam 2 Cam9, 10, uu 2 4._ ENGINE —_— —_ 25 Separate the carburetor assembly from the cylinder head, Unscrew the cam chain tensioner mount- ing bolt Unscrew twelve cylinder head mounting nuts and two 6mm flange bolts, and remove the head. Loosen the nuts uni formly in the reverse order of tighten: ing shown in Fig. Remove the cam chain guide from the cylinder by raising the cam chain guide slightly, and rotate the guide 90° and removing it toward the top. During this operation, do not drop the cam chain, 33 Unscrew the cam chain adjuster lock nut (Fig, 58) and remove the chain ten- sioner from the cylinder. To facilitate removal, raise the cylinder about 20mm/1in., and remove the cam chain tensioner. P Cam chain tensioner 2 Cam chain tensioner mounting bolt D Cylinder head D Cam chain guide ) Cam chain tensioner% — aie 14, Remove the cylinder. If the cylinder is tightly stuck pry the cylinder loose with a screwdriver placed in the groove at the base of the cylinder. 15, Remove the piston pin clip, piston pin, and the piston, Note: When removing the pin clip, exercise care not to drop the clip into the crankcase. 65 @ Piston pin clip 16. Remove the piston rings. 17. Sere a 6mm bolt into the rocker shaft and remove the rocker arm shaft from the cylinder head cover. B. Inspect 1. Inspect the camshaft bearing surfaces Camshaft bearing surfaces should be smooth and shiny. If it is seratched or excessively worn, it should be replacedHondadr 4 ENGINE GAIL AwSaR fromenntetiencom 27 Measure the height of the cam with a micrometer, Replace the camshaft if beyond the ser- viceable limit. Fig. 68 (P Micrometer @ Cam height Measure camshaft runout Support level both ends of the camshaft on V-blocks and with a dial gauge measure radial runout by rotating the shaft, Replace the camshaft if beyond the serviceable limit. Also check the camshaft for scratc! and replace if necessary. wear Fig. 69 @ Dial gouge @ Camshaft Measure cylinder diameter at the top, center and bottom in both the X and Y axes. Rebore the cylinder if beyond the serviceable |i at any point. When reboring the cylinder, rebore it to fit one of the four standard oversize pistons available Standard oversizes are 0.28, 0.50, 0.75 and 1.00 mm (0.009, 0.019, 0.029 and 0.039 in.) Fig. 70 @) Cylinder gauge Measure piston diameter. Measure the diameter at the piston ® skirt, 90° to the piston pin with a micro- meter. Replace the piston if the diameter beyond the serviceable limit Fig. 71 () MicrometerCourtesy Honda4Fun 28 “wrwwtthondafourcome /awihondastincom 4, ENGINE 7. Measure piston ring end gap. Insert the piston ring into the skirt of the cylinder so that it is squarely posi- tioned, and measure the gap with a feeler gauge Fig. 72 @ Piston ring 8 Measure piston ring side clearance. Install the rings on the piston and measure the side clearance of the pis- ton ring in the ring groove with a feeler gauge. Fig. 78 @ Piston ring @ Feeler gauge 9. Measure the piston pin hole using an ® us inside micrometer or cylinder gauge. 2 10. Inspect the piston for damage, distortion and excessive wear Fig. 74 @ Piston —@ Cylinder gauge4 ENGINE OhthcnletouSEnd famentatimenn 29 C. Reassembly 1. Install the rocker arm and the rocker arm shaft in the cylinder head cover Install the piston rings on the piston with the marking on the rings toward the top, Note: When ii ling new rings on the piston, roll the rings in the ring grooves to assure proper clearance. If the rings roll smo- othly, the clearance is satisfactory. Fig. 75 @ Marks @ Piston @ Piston ring 3. Install the piston on the connecting rod with the piston pin and clips so that the A mark on the piston head points toward the front (exhaust side) as shown in the figure. Note Always use new pin clips. 4. Stagger the end gaps of the top, 2nd and oil rings 120° apart. Install so that none of the gaps are on the piston boss axis or 90° away from it 5. Install the cylinder gasket, two dowel pins (orifice valve) and two O-rings on the upper crankcase. Note: Before installing the dowel pin, blow com- pressed air through the hole to assure that it is not clogged. Pig. 78 @ Cylinder gasket. i) O-rings 2) Dowel pinsx econ 4 nee 6, Turn the crankshaft and place the piston base (Tool No. 07033-55102) under No. 2 and 3 pistons, and install the piston ring compressors (Tool No. 07032. 30001) on the piston rings, and insert the pistons into the cylinder. When the No. 2 and 3 pistons have entered the cylinder, remove the bases and piston ring compressors. Next turn the crank- shaft slightly and install the No, 1 and fi 4 pistons being careful not to expose the Fig. 79 (@) Piston tases @ Piston ing compressors rings of the No. 2 and 3 pistons, Raise the cam chain at the same time. With the cylinder held approx. 20mm from the crankcase, install the cam chain tensioner in the cylinder, hold the tensioner down by hand and install the O ring, steel washer, and tighten the lock nut. Fig. 80 @ Cam chain tensioner 42@ Lock nut & Insert the cam chain guide into the cylinder as shown in Fig. 81. Fig. 81 Pine @ “UP” mark 9. Install the cylinder head gasket, two dowel pins and two O-rings on the cylinder, Fig. 82 (@ Cylinder head gasket @ O-rings @ Dowel pins.4Fun 4 ENGINE Quel twee fameamacincon 31 10. Place the cylinder head and hold the cam chain with a screw driver to prevent cam chain from dropping. 11. Tighten the twelve 8 mm nuts uniformly with the special tool (Tool No. 07078- 2301) to a torque of 2,0~2.2kg-m. (14,46~16.63 ft-Ibs) in the sequence shown in Fig. 83. Next, install and torque two 6 mm flange bolts, Mount the cam chain tensioner on the cylinder head with the aluminum washer and 6mm bolt Note: Exercise eare not to drop nuts or washers into the eylinder head as it will be difficult to remove them. 12, Hold the cam chain sprocket and cam chain together and slide the camshaft through them from the right side, and set it on the bearings in the cylinder head. Install the cam chain on the cam sprocket Fig, 81 () Cam sprocket Camshaft @ Cam chain 13. Remove the point cover, rotate the crankshaft in the clockwise direction and align the “T” (1.4) mark of the spark advancer to the timing mark. Next, position the camshaft so that the center of the cutout notch on the right end of the camshaft is aligned to the cylinder head flange surface. Fig. 85) Gylinder head flange surface 2) Cutout notch) Spark advancer 14, Mount the cam sprocket on the camshaft with two 7 mm bolts 15, Mount the carburetor assembly on the cylinder head. 16. Install the two dowel pins and six sealing rubbers on the cylinder head. Fig. 86 @ Dowel pins @ Sealing rubbers32 4. ENGINE ¢ valve tappet | adjusting screw 6 not properly contacting the valve Fig. & Fig. 8 @ 6mm screw 2) Chromium-plated copper washer 3) Head side cover set plate Alminum washer Fig. 89) O-ring HondaaFun Cour 17. Install the cylinder head cover with twelve 6mm screws and six 6 mm bolts, and torque to 0,8~1.2 kg-m (5. 78~8. 67 Ibs-ft) so that torque difference is not over 0.2kg-m (1.44 Ibs-ft). Note: + Insert fingers into the tappet hole cap opening and lift the valve tappet adjusting serew to check that they are properly meet- ing the valves. + Use the six 6mm copper washers as shown in Fig. + Install the head side cover set plate washers mounted on both sides of the 6 mm. screws (Chromium-plated copper washer on top and alminum washer on bottom) 18, Install O-rings on the dowel pins of the the left and right side covers, and install the side covers on the cylinder head. 19, Install the breather cover with six 6 mm screws, Note: High tension cord clips are mounted on both sides the clips facing forward, 20, Adjust the cam chain by referring to page 12. 21. Adjust the tappets by referring to page 7.4, ENGINE 4, VALVES AND VALVE SPRINGS A. Disassembly 1. Remove the cylinder head by referring to section 3. A. 2 Compress the valve spring with a valve spring compressor (Tool No. 07031-30011), remove the valve cotters, and the valves. 3. Drive the valve guide out of the eylinder head using the valve guide remover (Tool No, 07046-32301) 1. Remove the valve guide cap from the valve guide B. Inspection 1. Measure valve stem clearance. Insert the valve into the guide and measure the clearance in both the X and Y diree- tions using a dial gauge. Replace the valve and guide in set if clearance beyond the serviceable limit. Drive the guide into the cylinder head using a valve guide driver and finish ream the guide to the proper size. Standard valve guide inside diameter for both the inlet_and exhaust is 5.475~5.485 mm 0.2153 in.~0.2157 in.) Fig. 91 Fig. 92 Valve spring compressor Cylinder head 1) Valve guide remover 1 Valve B Dial gaugeCourtesy Honda4Fun 34 Surthondatourcom? /irwchondattincom —&, ENGINE 2. Fig. 93. @ Valve seat width 3 4 Fig. M1 @ Dial gauge — @ Valve 5, Fig. 95. @ Vernier caliper @ Valve spring Fig. 96 @ Straight edge @ Feeler gauge Measure the valve seat contact area, Apply a thin coat of bluing or red lead on the valve face, press the valve against the seat and turn. The imprint of the valve seat should be continuous around the face of the valve; if not, lap the valve and reinspect. If still unsatisfactory, recut the valve seat with a valve seat cutter. First, cut the inside seat an inside cutter, the top seat with a top cutter, and finally make the finish cut with a 90° cutter to produce a seat width of 1,0~1.5 mm (0.039~0.059 in.) Measure valve runout. Place the valve on V-block and measure the runout of the valve with a dial gauge applied to the face of the valve while turning the valve, Replace the valve if the runout beyonds the serviceable limit Measure the valve spring. Measure the free length of the valve spring with a vernier caliper. Measure the flatness of the cylinder head. Place a straight edge on the cylinder head surface and measure the clearance at several points with a feeler gauge If there is a clearance of over the service- able limit, lap the cylinder head surface on the surface plate using lapping com- pound or replace the head if it cannot be repaired.thei ‘in is 3 C. Reassembly 1. Wash all of the component parts in kerosene and reassemble the parts in the reverse | order of disassembly. Fig. 97 Component parts of the cylinder head D Exhaust valve @ Valve spring outer seat ® Retainer » Inlet valve @ Valve spring inner seat ® Cotter 9) 10x1 mm O ring Valve stem seal Gy Valve rocker arm shaft © Exhaust valve guide Inner valve spring a Valve rocker arm © Inlet valve guide ® Outer valve spring Note: When installing the valves, apply a liberal amount of oil on the valve stem. 2 Install the cylinder head in accordance with section 3. C.% ec ccs «even . i Lubricating System Block Diagram 5. Oil Pump and Oil aoe is Filter [Cam profile} {Rocker arm slipper|{Rocker arm shaft}{ Valve stem} Theoil pump isa trochoid [Gaia tearing type driven by the pri- TE Rextsiser mary shaft. Screen and ‘Crankshaft bearing}—{ Connecting rod bearing Piston_pin}-—{ Piston’ paper element filters are merle Destin “a 3g} {Piston pin [Piston Hed ponds Hen el PEE] | [FTE Tol + lrecea mee a to the engine, rs [Git iter | Primary gear} Gi pomp} {Re ware (Sipe Gee] Sea esa} —— Pie o- [OT pan) ‘Transmission main shalt + {Gam chain || Fig. 9§ Oil Lubricating Diagram @ Oil cleaner element “Oil pump @) Relief valve @ Oil sereen filter4 ENGINE Sourtes Grane » Disassembly 1. Drain the engine oil in accordance with section 2. A. 2 Remove the starting motor cover and j the left crankcase cover. 3. Unscrew the 4mm bolt and remove the pressure switch wiring. Next remove three 6mm screws, and the oil pump, : Fig. 99°) 4mm tlt 4. Remove the cap and disassemble the re- lief valve and spring. Fig. 100 Oil Sereen Filter 1. Drain the engine oil in accordance with section 2. A. 2, Unscrew ten 6 mm bolts from the oil pan, Remove the oil pan, and the oil screen filter can be removed Fig. 101 (Oil screen filter3g Courtesy 4, ENGINE L a B. i Fig. 102 @) Feeler gauge 3) Outer rotor 2 Inner rotor 2, Fig. 103. 4) Feeler gauge @) Outer rotor @ Pump body a 4 Fig. 10) Relief valve seat Drain the engine oil in accordance with section 2. A. Unscrew the center bolt to remove the oil filter. Inspection Measure the clearance between the inner and outer rotors. Use a feeler gauge to measure the clearance between the rotors. If the clearance beyonds the serviceable limit replace the pump. Measure the clearance between the outer rotor and the pump body. Use a feeler gauge to measure the clearance between the outer rotor and the pump body. If the clearance beyonds the serviceable limit, replace the pump. Inspect the operation of the relief valve. Make sure that the relief valve is not stuck in the pump body. Also check for any foreign objects which may be lodged between the valve and seat. Inspect the screen filter Wash and inspect the screen filter. place the filter if damaged Re.C. Reassembly Oil Filter 1. Insert the oil filter center bolt through the oil filter case and assemble the spring, spring seat and element. Screw the center bolt into the engine Oil Screen Filter 1, Mount the screen filter on the lower crankcase. 2 Mount the oil pan on the engine with ten 6mm bolts. Oil Pump 1. Insert the drive pump shaft into the oil pump body and install the drive pin into the shaft. Align the outer and inner rotor punch marks and install into the pump body (the surfaces with the punch marks may be set to the pump body side or the pump cover side). & Install the 47mm Oring on the oil pump body and install the oil pump cover with three 6 mm screws. 4 Install the relief valve and spring into the oil pump body, and install the cap, 5 Install the two O-ring collars, two 14 mm O-rings, and a 47 mm O-ring into the oil pump body and then install the oil pump on the crankcase with three 6 mm sere! Connect the pressure switch wires. Install the left crankcase with four 6mm screws, and the gear change pedal, & Install the starting motor cover. pe ®o @ ® ®6OOo Fig. 105 4) Oil filter center bolt) Filter element set 2) 152. 5mm O-ring spring Oil filter case © Oil filter spring seat @ 89%4.5mm O-ring Oil filter element O} Fig. 106) Punch marks Fig. 107 @ 47mm O-ring @ Oil pump cover Fig. 108) O-ring collar) 47mm O-ring @ Mmm O-ring40 Courtesy . A se 4, ENGINE Fig. 109 Bolts Fig. 110 @) 25 mm snap ring 2 Clutch assembly Fig. 111 @) Clutch adjuster Fig. 12 @ Clutch lifter rod 6. CLUTCH Disassembly Drain the engine oil in accordance with section 2. A. Remove the kick starter pedal Unscrew ten 6mm screws and remove the clutch cover. Unscrew the four clutch pressure plate mounting bolts, and remove the clutch pressure plate and four clutch springs. Remove the clutch lifter joint piece Remove the 25mm snap ring, shims (some engine may not have shims installed), and the clutch assembly from the main shaft Disassemble the clutch disc, clutch plate and clutch center from the clutch outer. Remove the left crankcase cover. Disconnect the clutch cable from the clutch lifter. Unscrew the clutch adjuster lock bolt and remove the clutch adjuster from the left crankcase cover. Pull out the clutch lifter rod«ai ‘iA a * S (taperin Measure the thickness of the friction disc. Measure the thickness with a vei caliper and replace if beyond the service- able limit. Fig. 113 () Friction die @ Vernier caliper Check the clutch plate for warp. is Place the clutch plate on the surface plate and measure the amount of warp using a feeler gauge. If the warp be- yonds the serviceable limit, replace the clutch plate. 3. Measure the clutch spring. Measure the free length of the clutch spring with a vernier caliper and replace if beyond the serviceable limit. Fig. 114 @ Clutch plate @ Feeler gauge 4 Inspect the rivets mounting the clutch outer to the driven gear for looseness, and replace the clutch outer if any of rivets are loose. Fig. 115 @ Driven gear @ Rivets B Clutch outer2 ee omens Fig. 116 Pig. 117 Fig. 18 Fig. 119 D Clutch lifter 1) Clutch center 25 mm snap ring a @ Joint piece ® Adjuster @ Clutch outer ® Shim 4, ENGINE Cc i Reassembly Assemble the clutch lifter rod into the main shaft so that the spherical end is toward the right side, Apply grease to the clutch lifter and assemble it to the left crankcase cover together with the adjuster. Tighten the lock bolt and reconnect the clutch cable to the clutch lifter. Set the steel ball into the clutch lifter and mount the left crankcase cover with four 6mm screws. Apply engine oil on the friction dises and assemble them on the clutch center alternately with the clutch plates. Final- ly assemble into the clutch outer. Install the clutch assembly on the main shaft and the 25mm snap ring. Place a dial gauge against the end of the clutch assembly to check for looseness in axial direction. If the measured value greater than 0.1mm (0,004 in,), install a shim on the inside of the snap ring. Shims are available in the thicknesses of 01, 03, and 0.5mm. . Insert the clutch lifter joint piece into the main shaft, and fix the clutch plate with four clutch springs, washers, and 6mm bolts. Install the clutch cover with ten 6mm screws,4, ENGINE GEAR SHIFT MECHANISM Disassembly Disassemble the clutch in accordance with section 6, A. Remove the gear change pedal Hold the gear shift arm down while re- moving. Loosen the shift drum stopper bolt and remove the shift drum stopper. Next, unscrew the 6mm flat head serew and remove the stopper cam plate. Separate the upper and lower transmis- sion cases, and disassemble the transmis- sion gears in accordance with section 9. A. Remove the neutral stopper switch from the gear shift drum. Remove the shift drum guide screw from the upper crankcase, and remove the spring cap and the ball. Remove the guide pin clips and guide pins, and pull out the gear shift drum from the crankcase. — a D Gear shift arm Fig, 120 Fig. 121 (D Shift drum stopper bolt Shift drum stopper 3) Gm flat head screw @ Stopper cam plate Fig, 122 D Shift drum guide screw } Guide pin clip 0) Gear shift drum 2) Guide pin“ el ic a Fig. 124 @ Gear shift drum @ Micrometer Fig. 126) Gear shift forks @ Gear shift drum ass @ Fig. 127 @ Guide pin clips B. Inspection 1, Measure the diameter of the gear shift drum with a micrometer and the shift fork with an inside micrometer. Replace any part which exceeds the serviceable limit 2, Measure the width of the gear shift fork fingers with a micrometer. Replace if beyond serviceable limit, C. Reassembly 1. Set the left, right and center gear shift forks into the upper crankcase as shown in Fig, 126, then install the gear shift drum, 2, Insert the guide pin into the shift fork and fix it with the guide pin clip. Note: ike sure that the guide pin clip stalled in the proper direction.onda Sie ue Courte: 4. ENGINE Shwwhontatoursom 3. Place the counterbored section of the © shift drum as shown Fig, 128, and install the steel ball, the spring cap, and the ® spring then lock with the shift drum ®@ screw. ® Next, bend up the tab on the guide screw ® lock washer to lock the guide screw. © @® Fig. 128 @ Guide screw @ Spring D Guide screw @) Spring cap Teck washer @ Stee! ball ® Orring Counterbored seetion 4, Align the neutral switch to the groove in the gear shift drum and lock in place with the 6 mm screw. Fig. 129 @ Gear shift drum 5. Assemble the transmission into the upper crankcase in accordance with section 10. C, and assemble the upper and lower crankcase. 6 Install the cam plate on the pin of the gear shift drum with the 6mm flat head serew which has been coated with thread lock cement. Note: The pin and the pin hole in the cam plate must be aligned. 7. Insert the spring into the shift drum stop- per, install the end of the spring into the crankcase groove as shown in Fig. 131, and tighten the shift drum stopper bolt. After tightening the bolt, make sure that the shift drum stopper operates smoothly. If there is excessive vertical looseness the shift drum stopper should be replaced Fig. 1314, ENGINE |e 8 Install the gear shift arm and make sure that it operates smoothly in both direction. 9. Install the clutch in accordance with section 6. C. 8. CAM CHAIN TENSIONER ‘The cam chain tensioner is constructed of spring steel on which a layer of heat resistant rubber is vulcanized and a sheet of teflon cemented. It applies pressure against the cam chain and absorbs the shocks produced by the chain. The cam chain guide on the tension side of the cam chain also controls chain vibration. An adjustment screw is located at the rear of the cylinder block. Fig, 132 Cam chain guide ® Lock nut @® Cam chain tensioner @ Screw4, ENGINE A. Disassembly 1, Remove the cam chain tensioner and the chain guide in accordance with section 3A. B. Inspection 1. Make sure that the gear of the cam chain tensioner adjuster is properly meshed with the rack, and inspect for smooth operation, C, Reassembly 1. Perform reassembly in accordance with section 3. C. 9. CRANKSHAFT AND CONNECTING ROD ‘A. Disassembly 1. Dismount the engine in accordance with section 2. A. 2. Disassemble the cylinder head, cylinder, and piston in accordance with section 3. A 3, Remove the generator cover and remove the rotor using a generator rotor puller. (Tool No. 07011-21601) 4, Remove the point cover, and the special washer by removing the Gmm_ bolt Next, unscrew the three 5mm. screws and remove the contact breaker assembly and the spark advancer. 5. Remove the clutch and the gear shift arm in accordance with section 6. A. 6 Remove the starting motor cover, and dismount the starting motor. Honda4Fun Courtesy é Fig. 133 @ Gear Fig. IM (2) Generator rotor 3) Generator rotor puller mm bolt Special washer Contact breaker assembly D Starting motor4g Courtesy HondagFun (rw heweeteur eng /Gaecendettmcem 4, ENGINE Place the engine upside down and un- screw the ten 6mm bolts to remove the oil pan, 8& Unscrew ten 8mm bolts and twelve 6mm bolts from the lower crankcase. Loosen the 8mm bolts in the reverse order shown in Fig. 151. 9. Then, put the engine in correct position and unscrew three each 8 mm and 6mm bolts, Tap the upper crankease lightly with a wooden hammer and separate the Fig. 157 (Bearing aot plate upper and lower crankeases. 10. Unscrew two 6mm bolts and remove the bearing set plate 11. Pull out the primary shaft using a primary shaft puller (Tool No. 07009 32301). Note: Disassembly of the primary shaft, trans- mission, and kick starter can be per- formed without removing the cylinder head, cylinder or piston. When remov- ing lower crankcase, follow the sequence 10, 11, 9 and 8 above. Fig. 188 (Primary shaft @ Primary shaft puller 12, Remove the starting clutch from the primary chain, 13, Remove the primary chain and the cam chain from the crankshaft, B. Inspection 1. Measure crankshaft runout Support both ends of the crankshaft on V-block and measure the amount of bend in the crankshaft by applying a dial gauge to the center journal and rotating the crankshaft. If the runout beyonds the serviceable limit on the dial gauge, the crankshaft should be replaced. Fig. 139 @ Primary chain @ Starting elutch 2, Inspect the crankshaft journals for scoring. and uneven wear with a micrometer. If any journal is out-of-round or tapered more than serviceable limit, the crankshaft Fig. M0 @) Dial gauge @ Crankshaft should be replaced.3. Measure the crankshaft journal wear. Cut a length of plasti gauge to the width of the bearing cap. Place the gauge on the bearing parallel to the crankshaft, assemble the crankshaft and torque down the crankcase in accordance with Fig. 151 Disassemble the crankcase and measure the plasti gauge using the scale provided If there is a clearance in excess of 0.08 mm (0.0031 in,), the bearing should be replaced. Note: When measuring with the plasti gauge, do not turn the crankshaft. Selection of The Bearing 1, Remove the bearing, assemble and tigh- ten the upper and lower crankeases. Refer to Fig. 151. Measure the inside diameter of all the bearing seats in the vertical direction with inder gauge and select out the corresponding alphabet from the table below. EOE ay 1 4179~1. 4182) 26. 016 Measure the diameter of all the crankshaft journal with a micrometer and also select out the corresponding figure 1 or 2 from the table below. T 2 96~22, 09 32, 99~ 7a83~1, 2087) (12887 4. According to the alphabet and the figure from item 2 and 3, pick out the proper bearing from A, B, C and D. Transat lasifcation No. [crankcase sification marke B x c (Brown) | (Black) c B B (Green) (Brown) c D = (Yellow) | (Green) Courtesy of HondasFun Tatton AP 13 Note: ‘The lower crankease and crankshaft are marked with letters or number at the factory. ‘These are production codes and should not be used or refered to during servicing or repair.HondagFun Courtesy dHondag run 50 “riowdatour een Fig. 14 (1) Connecting rod cap NGINE 5. Measure connecting rod large end wear. Separate the cap from the connecting rod and after setting the plasti gauge in place, torque the two rod nuts to 2.0-2.2 eg-m (14.46-15.91 Ibs-ft) Disassemble the cap and measure the plasti gauge. Replace the bearing with new one if beyond the serviceable limit Note: Do not turn the crankshaft while the plasti gauge is installed. o- Fig. 145 @ Connecting rod code number Fig. 6 @ Key (projection) Selection of The Bearing 1, Measure crankshaft pin diameter with a micrometer and select out the corre. sponding alphabet from the table below. aA B 34, 90~25, 00 94, 98~34, 99 1. 3775~1, 3780) 5 1.37711, 3775) 2. Select out the bearing from the table below which coincides with the number (1, 2, 3) stamped on the large end of the connecting rod. Take lassification marl Conriectin 4 8 rod code No. a B (Brown) |A (Black) Green) |B (Brown) D (Yellow) |C (Green) Note: +The numbers marked on the crankshaft are production codes and should not be referred to during servicing. +The bearings must be installed on the connecting rod with the key toward the front.HondaaFun 4, ENGINE chondatun com 6. Method of designating connecting rod weight When replacing connecting rod, re- place with one having the same weight code. The weight code is stamped at the large end of the connecting rod When replacing all of the connecting rods, the tolerance of the respective rods should be within 5 grams. Note: © In the connecting rod weight, that weight 311~315 of cap and two bolts are included but does Fig. 147) Weight code number SSS” not include the bearings. 7. Measure axial clearance using a feeler gauge. Replace if beyond the serviceable limit ‘Weight (gr) A BLA 285 B 286~200 € 201~205 D 296~300 E 901~905 FE 306~310 Fig. 148.) Fecler gauge @) Connecting rod & Measure the connecting rod small end. Measure the diameter of the connect- ing rod small end with an inside dial gauge. Replace if beyond serviceable limit. @ Fig. 149 (i) Inside dial gauge C. Reassembly Install the primary chain and cam chain ‘on the crankshaft. Install the crankshaft into the lower crankcase. 3. Position the starting clutch and starter gear as in Fig. 150,then drive the primary shaft in from the right to left. Exerci care in the needle bearing assembly sequence shown in Fig, 165. Fig. 150° @ Starting clutch @ Starter gear @) Primary shaftTtmetctameen 4 ENGINE 4, Install the bearing set plate with two 6mm bolts. 5. Apply a thin coat of gasket paste on the mounting flange of the lower crank- case (heavy coat will cause the paste to fall inside the crankcase). Install two dowel pins, mount the up- per crankcase on the lower crankcase. Fig. 162, 6 mm mounting bolts 6. Place the engine upside down so as not to separate the parting surfaces by hold- ing them by hands and install the ten Fis. 189 Simm bolts 8mm bolts. Torque the 8mm bolts in 2: saat bales the sequence shown in Fig. 151 toa torque of 23-25 kg-m. (16,63-18.08 Ibs-ft). jext, tighten thirteen 6mm bolts. (Fig. Note: Note position of the two 8mm bolts which are stamped on the bolt head with numeral oe 7. Position the upper crankcase on top and install with three each, 6mm and 8mm bolts. (Fig. 153) Note: Fig. 154 @ Oil pan Note position of the two Smm bolts which are stamped on the bolt head with numeral oo 8 Install the oil screen filter and mount the oil pan with ten 6 mm bolts. 9, Mount the starting motor with two 6 mm screws 10, Install the gear shift arm in accordance with section 7. C. 11, Install the clutch in accordance with section 6, C. 12, Insert the spark advancer dowel pin into the pin hole in the crankshaft, and then mount the contact breaker with three 5 Fig. 155 @) Dowel pin hole @ Dowel pin mm screws,13, 14, 4, ENGINE Install the special advancer washer with the 6mm bolt, and install the point cover. Mount the generator rotor with the 16mm bolt. Install the generator cover. ‘Assemble the piston, cylinder, eylinder head, and head cover in accordance with section 3. C. ). TRANSMISSION, KICK STARTER AND PRIMARY SHAFT Disassembly Dismount the engine from the frame in accordance with section 2. A. Remove the clutch in accordance with section 6, A. Separate the upper and lower crankcase in accordance with section 9. A Remove the transmission and disassemble the gears from the respective shafts ‘k Starter Remove the 18mm snap ring and the return spring. Remove the 12mm snap ring and dis- assemble the kick starter shaft from the lower crankcase. seria nin a Fig. 156 @ Generator rotor 2 16mm bolt Fig. 157 @ 18mm snap ring @ Return spring Fig. 158 @ 12mm snap ring @ Kick starter shaftcourt 1 54 SotrnetdetewSind fameceentneen 4, ENGINE A Primary Shaft o 7. Remove the primary shaft in accordance with section 9. A, and remove the 20 mm snap ring and primary drive gear. Fig. 159.) Primary drive gear @ 20mm snap ring 8 Remove the side collar and pull out the #6205 ball bearing. 9. Remove the 30mm snap ring, primary driven sprocket, starting clutch, and pull out the damper rubbers. Fig. 160 @ 30mm snap ring - 2 Primary driven sprocket 10. Unscrew the three 6mm flat head screws and remove the starting clutch outer. Fig. 161) 6mm Sat head screws 2 Starting clutch outer B. Inspection 1, Measure gear backlash, Fig. 162 © Dial gauge Set the pointer of a dial gauge against the tooth of the gear and measure the backlash.4. ENGINE 2 Inspect the dogs and replace any gears with excessively worn dogs. Also, make sure that the gears slide smoothly over the splined shaft. C. Reassembly imary Shaft 1. Install the starting clutch outer and prim. ary driven sprocket hub with the three 6mm flat head screws coated with thread lock cement, and then stake the screw heads with a punch to prevent loosening. 2 Assemble the damper rubbers on the primary driven sprocket, and install on the starting clutch with 30mm set ring. 3 Drive the #6205 ball bearing into the primary shaft. 4 Mount the starting clutch gear on the starting clutch, insert the needle bearing and 25 mm spacer into the starting clutch gear, fit the 25mm thrust washer and the snap ring on the primar shaft, and install the primary shaft in the crank- case en crs « Fig. 163 g Fig. 164 1 6mm flat head screw D Primary driven sprocket 2) Damper rubbers DQOOOO Fig. 165 ® Starting clutch gear B Needle bearing (25% 2917) mm 25mmKick Starter 5. Reassemble the kick starter components in accordance with Fig. 166. Note: Do not forget to install the 18 mm washer. 6. Assemble the transmission gears on the respective main and counter shafts. HondaaFun Som] /iitichondatfuncom 4. ENGINE @ Starter pinion set spring @ Kick starter rachet 5 15mm thrust washer © Kick starter rachet spring, © Rachet guide plate (@ Chain guide thrust @ 12mm soap ring @ 18mm @ 18mm snap ring @® Kick starter spring 1 Kick starter spindle D Stmm bearing set ring 25mm snap ring pecial ball bearing @ 2.5mm O-ring © Transmission counter shaft © 33x 57%7 oil seal Di Drive sprocket fixing plate ® Gear shift fork pin ® 20mm needle bearing @ Counter shaft low gear 407) ® Counter shaft fourth gear (297) @@ 25mm thrust washer Counter shaft third gear (@sT) 25mm lock washer gear (96) ® Counter shaft top gear (rT) @ 52mm bearing set ring © 5205 HS ball bearing % Transmission main shaft (a7) @ Main shaft fourth gear (237) @ Main shaft second, third gear (227, 267) &@ Main shaft top gear (307) @ 20mm thrust washer & 22mm needle bearing @ 8x34 oil seal Fig, 167courte: HondasFun 4, ENGINE owen FA, 7 7. Install the two each bearing set rings and the dowel pins in the upper crank- case, and install the transmission & Reassemble the upper and the lower crankcase in accordance with section 9. C. Install the clutch in accordance with sec: tion 6. C. Mount the engine in the frame in ac: cordance with 2. B. ” Fig. 168 @) Bearing set rings @ Dowel pins ll. CARBURETOR A. Disassembly L Remove the carburetor unit from the engine in accordance with section 2. A. Stay Plate And Carburetor 2 Unhook the throttle return spring off the link lever. Note: Exercise care not to damage the hook end Fig. 169 (i) Throttle return epring of the spring. 2) Link lever 3 Unscrew the hex. nuts, and remove the dust plate B. Remove the cap nuts Fig. 170 @ Hex. nuta Cap nuts ®) Dust plate BTtmecstimeon 4. ENGINE 4, Remove the adjuster holders from the link arm, 5. Unscrew the eight 6mm flat head screws from the stay plate and remove the carbu- retor unit Fig. 171 @ Link arm @ Adjuster holders | Throttle Valve And Jet Needle 6. Unscrew the two carburetor top mount- ing screws from each carburetor and re- move the tops. D Carburetor top 7. Position the throttle valve to full open and straighten the tab of the two tongued washers, Fig. 173 @ Tongued washer “8 Remove the 6mm bolt from the shaft end and remove the link arm in direc- tion A using a screw driver. Fig. 174 @ Link arma 4 ENGINE RinherlstuSing famematincon — 59 9, Loosen the 6 mm bolt on the throttle side about 1/2 turn, insert a screwdriver be- tween the throttle shaft and link arm and pry loose in direction A. Pig. 175 @ 6mm bolt ® Link arm 10. Unscrew the two 3mm screws, rotate the valve plate 90° in either direction and align the tab on the valve plate to the groove in the shaft, and remove the valve plate. 11. Remove the jet needle from the throttle valve. Fig. 176 @ 3mm screws @ Valve plate os 1. Remove the carburetor from the stay plate in accordance with section 1~6. 2. Remove the adjusting screw from the adjuster holder, @ Adjusting screw @ Adjuster holder 3. Position the throttle valve at the inter- mediate position and remove the adjuster holder. Fig. 178 @ Adjuster holder— Fresco pwee Float, Main Jet, And Slow Jet 1, Remove the float chamber body. Remove the leaf spring and the main jet. Fig. 179 @ Leaf spring @ Main jet 3. Pull out the float arm pin and remove the float, 180 @ Float —@ Float arm pin 4, Disengage the clip plate and remove the valve seat, Fig. 181 @ Valve seat @) Clip plate B. Inspection 1, Fuel level adjustment. Position the float so that the float arm barely touches the tip of the float valve. Measure the distance from the flange to the top of the float with the float level gauge. The standard value is 22mm (0.89 in.) Fig, 182 @ Floats @ Float level gaugeSe 4znone Se C. Reassembly Carburetor wetting data Float, Main Jet, And Slow Jet Seen =| Main jet 1. Install the valve seat with the clip plate, — 4 2. Install the float. eR 3. Place the leaf spring on the main jet, | Sow jet and install them on top of the needle | y, se valve jet holder. 4. Install the float chamber body. | Adjuster Holder 1. Insert the coil spring B and spring seat B into the adjuster holder. Position the throttle valve to about 1/2 open and in- sert approximately 1/4 of the connector shaft into the holder window. Install them while holding the spring seat down with a thin screwdriver 2, Mount the carburetor on the stay plate in accordance with section 7 and 8 | Throttle Vaive And Jet Needle 1. Install the jet needle on the throttle valve 2. Place two each spring washers and 3mm screws on the valve plate, and then place the tab of the valve plate to the slot of the throttle valve and push down to the bottom, Then rotate the valve plate 9° toward the link arm and install the 3mm screws. 3. Install the throttle valve in the carbur- etor body so that the throttle valve cut- away section is toward the choke valve Air screw opening, Fig. 183, Fig. 184 Fig. 185 D Adjuster holder 2 Coil spring B D Valve plate 2) $mm screw D Cutaway section 3) Spring seat B D Spring washer 4 Throttle valve 3) Choke valveGF ressre . D 6mm bolt 2) Throttle shaft 3) Link arm Fig. 187 © Tongued washer Fig. 188 (1 Rubber pipe @ T type joint Fig. 189 @ Return spring Spring set plate ENGINE 4, Unserew the 6mm bolt from the throttle shaft and push the spherical end of the link arm into the throttle shaft while pulling up the throttle shaft. 5, Install the tongued washer with the tongue positioned as shown in Fig. 187, tighten the 6 mm bolt, and then bend up the washer tongue against the bolt head. 6, Install the carburetor top with the two 5mm screws, 7. Combine the two carburetors with the T type joint and the rubber pipe. 8 Mount the spring set plate, and then hook up the return spring. Position the four carburetors, install the set plate, and tighten with the eight Gmm flat head screws.4. ENGINE 9. Install the dust plate A, and mount the adjuster holder to the link arm, 10, Insert the coil spring B and tighten it with the cap nut 11. Install the special washer D, dust plate B, and flat washer on the adjuster screw and tighten with the nuts. 12, Connect the throttle return spring on the link lever, being careful not to damage the hook 13, Install and route the two fuel tubes as shown in Fig, 193. 14, Mount the carburetor unit on the engine in the reverse order as described in section 2A 63 Fig. 190 D Dust plate A @) Link arm 3) Adjuster holder Fig. 191 ® Coil spring B Cap nut Fig. 192 (Special washer D 2 Dust plave B Fig. 193, D Fuel tuber“5. cHassis | eles 1. FRONT WHEEL AND FRONT BRAKE D Fig. 194 D Axle shaft @ 515mm oval serew @ Speedometer gear box @ 8% 102 mm bolt 5) Gear box retainer cover © Gear box retainer ® Oring @ 6902 R ball bearing @® Front axle distance collar ® Front spoke B 4 Front wheel hub @® Front wheel tube @ Front wheel tire G Front tire fap 1 Wheel balancer 4 Front spoke A o> Front wheel sim ® 6302R ball bearing ® 22368 dust seal ® Front wheel bearing retainer ® Front wheel collar @ Front wheel axle nut Front Wheel A. Disassembly 1, Place a suitable block under the engine to raise the front wheel off the ground 2, Disconnect the speedometer cable from the speedometer gear box. 3 Unserew the axle holder mounting nuts and remove the front wheel assembly from the front forl 4, Unscrew the front wheel axle nut and remove the front axle, es ‘ ve 1) Front axle nut Fig. 195 @ Spectometer cable Fig. 196HondaaFun en fondettimceen 5. CHASSIS Remove the bearing retainer from the wheel hub, and the dust seal from the bearing retainer. 6. To remove the brake disc from the wheel, first, straighten the tongues on the tongued washers, and unscrew the dise mounting nuts Remove the speedometer gear box and retainer cover from the opposite side. 8 Remove the front wheel bearing. Fig. 198 @) Disc mounting nuts 2) Tongued washers B. Inspection 1. Checking the brake disc Place the disc on a surface plate and measure the trueness using a dial gauge as shown in Fig. 199. Replace the disc if beyond the serviceable limit. Fig. 199 @ Dial gauge Front brake dise 2. Checking rim wobble and wheel runout Spin the wheel by hand and check both wobble and runout using a dial gauge 200. as shown in Fig.Sou ; «casas = _ % Checking the wheel bearings Measure bearing wear in both axial and radial directions Check for loose or bent spokes. Tighten loose spokes, and straighten or replace bent spokes. If tire pressure is low, check for leaks around the valve stem and also the valve. Check the condition of the tire both inside and outside for cuts, bruises, and imbedded nails Reassembly Drive the 6302R wheel ball bearing into the hub using a bearing driver. Install the dust seal in the wheel bear: ing retainer, mount the retainer into the wheel hub, and install the O-ring into the hub, Install the gear box retainer cover on the gear box retainer so that the cover matches the slot. Mount the brake dise on the wheel with bolts, tongued washers, and nuts. After tightening, bend up the tongues on the washers to lock the nuts. Fig. 201 Dial gauge @ Ball bearing, Fig. 202 (@ Bearing driverCourtesy HondaaFun 68 wwrhondetoursom( /Aschondadtn.com 5, CHASSIS 5, Install the speedometer gear box on the opposite side of the brake disc, and insert front axle into the hub through the speedometer gear box. 6. Mount the front wheel on the front fork, install the axle holders, and tighten the nuts Note: Make sure that the speedometer gear box is mounted in the proper position, First tighten the axle holder on the left side (brake disc side, and then the right ide. Connect the speedometer cable to the gear box. & Checking the wheel balance a. Mark the side of the tire and rotate the wheel lightly several times and observe the position where the mark comes to rest b. If the wheel is not statically balanced, the mark on the tire will come to est at the same position. (heavier section will be at the bottom) Fig. 206 @) Balance marking @ Balance weight c. Attach a balance weight on the spoke at the lighter section (at the top), d, The wheel is in balance when it does not stop at any definite position after rotating the wheel several times, The balance weights are available i four different weight sizes (5, 10, and 20 gr). e. The front wheel should be balanced with the brake disc installed Fig. 207 Front dise brake ‘The disc brake system consists of the brake lever and master cylinder on the right handle bar, caliper mounted on the front fork left side, and the special stainless steel brake disc mounted on the wheel hub. (Operation) 1. When the brake lever @ is gripped, the cam @ at the base of the lever actuates a piston of the master cylinder. 2. The piston moves the primary cup @ which, blocks the passage to the reservoir and pressurizes the fluid within the master cylinder. ‘This pressure is transmitted to the caliper chamber through brake hose B @, 3 way joint ®, and brake hose A@. Also, the stop light pressure awitch © mounted on the 3. way joint is actuated. 3. The hydraulic pressure within caliper chamber A applies pressure against piston ®, which forces pad A 00 against the brake disc. Since the caliper assembly is mounted on an arm which pivots at the front fork, it is free to swivel, therefore, the reaction from pad A 4 is transmitted to pad B, resulting in equalized ‘pressure being applied by the pads to both sides of the brake disc.cuss Stee Fresco , Front brake lever Eront brake lever cam Primary cup Front brake hose B A. Disassembly Remove the front wheel. Unscrew the oil joint bolt and disconnect the brake hose. Fig. 209°) Oil joint Unscrew the three caliper mounting bolts and a caliper adjusting bolt, and remove the caliper assembly Unscrew the two caliper set bolts and separate caliper A and B. @ Caliper B 5 Caliper A70 Rtleu and ferosmnttncen 5 5. Remove pad A and piston from caliper ll # Gi Remove pad B fremncaliper Bi Fig. 211 (2) Caliper A 8) Piston Uns and remove the brake hose. 8, Unscrew the master cylinder mounting bolts and remove the master cylinder unit from the handle bar. 9. Disassemble the master cylinder. rew the master cylinder joint bolt Fig. 212 Joint bole 2) Master eylinderunit ® Brake hose @ Master eylinder mounting bols Brake lever cap ® Piston 1B Reservoir cap {@ Gmm hex bolt 3) Brake lever © Secondary cup 4 Master cylinder plate 9 Joint holt washer 3) Stopper washer ®) Primary cup 1 Diaphragm 30 Joint bolt © Boot i Spring te Matter eylinder body @ Front brake hose 5) 18mm internal snap ring 1 Check valve 2 Master eylinder holder ® 10.5mm washer & Handle lever pivot bolt, Go Gmm spring washer Fig. 213Courte: HondasFui - a cHASsIs uterliewstemd (ioumacanen 71 10, Remove the boot and remove the snap ring from the master cylinder body. Next, remove the 10.5mm washer, piston, secondary cup, spring, and check valve Fig. 214 () Mastereylinder body <4) Special pliers ® Snap B. Inspection 1. Checking the wear of the dise brake pad. Red grooves are provided for both pad A and B as a wear limit indicator. When the pad is worn to this red groove, the pad should be replaced. After re placing the pads, adjust the clearance between the brake dise and pad to 0.15 mm (0.006 in.) with the caliper adjusting bolt. Adjust by turning the caliper adjusting bolt until the pad drags slightly against the brake dise, and from this position back off 1/2 turn and tighten the lock nut @ ® 0.15mi 9.606 Fig. 215) Pal B@) Brake dine 2 Pal A @ Wear limit indicator 2. Checking the caliper cylinder and piston, Measure the inside diameter of the caliper cylinder and the outside diameter of the piston using a cylinder gauge and a micro- meter. If the clearance is greater than serviceable limit, replace the part. Fig. 216°) Caliper cylinder @ Piste 2 Cylinder gauge @ MicrometerHonda4Fun Thondastimacom 5, CHASSIS 72 3. Checking the master cylinder and piston Measure the inside diameter of the cylin- der and the outside diameter of the piston using cylinder gauge and a micro- meter. If the clearance is greater than serviceable limit, replace the part C. Reassembly 1, Perform reassembly in the reverse order of disassembly wy 2. Assemble pad A and B. 1 Master cylinder @ Cylinder gauge Note: Apply silicone sealing grease on the pads sliding surfaces of the caliper before as- semblying pad A and B. This serves as a dust preventative as well as water re- pellent. Do not apply grease on the pad friction surface. 3. Mount the caliper assembly on the front fork. 4, Mount the master cylinder unit on the handle bar. 5. Fill the master cylinder reservoir with SAE J1703a brake fluid. Fig. 218 @ Caliper B 3) Pad A ® Pad B i) Caliper A D. Brake adjustment When the brake has been disassembled al- ways perform the air bleeding operation of the hydraulic brake and then acljust the brake. 1. Brake lever free play Lever free play of 2~5mm (0.08~0.2 in.) measured at the end of the lever is normal. If the play is excessive, inspect the brake system and replace any worn or defective part. 2. Brake fluid level Fill the reservoir with brake fluid to the level line, Note Brake fluid will damage paint finish, rubber parts, and meter components, therefore, exercise care in handling and immediately wipe in case of spillage. Fig. 220 @ Diaphragm) Master @) Brake tid5. CHASSIS 3. Air bleeding the brake system When air enters the brake hydraulic system, braking effectiveness degrades and creates a hazardous condition. If brake lever action becomes soft or spongy, or if the Quid reservoir is allowed to become dry, perform the bleeding in the following manner. a, Fill the reservoir with brake fluid up to the level line. b, Install the diaphragm to prevent loss of brake fluid, c. Attach a bleeder tube to the bleeder serew and place the opposite end into a vessel to catch the fluid d. Pump the brake lever several times, and open the bleeder screw a half turn while maintaining a grip on the brake lever. When the lever bot- toms, first, close the bleeder screw before releasing the lever. Repeat this operation several times until there are no air bubbles in the fluid which flows out of the bleeder tube. Note: Replenish the fluid in the reservoir and do not allow the reservoir to become dry as it will permit air to enter the brake hydraue lie system. 2. REAR WHEEL AND REAR BRAKE @ O-ring @ Wheel damper A i) Wheel damper B ® Final driven flange @® Distance collar B & 6305 U ball 4® Bearing retainer & 1048 driven sprocket i ‘9 34560 oi! seal 2 Oring &) Sprocket side plate Tongued washer 3 10mm nut } Tire fap Wheel hub i Side collar Courtesy HondaaFun 73 Fig. 221 D Front brake lever 2) Reservoir cap ® Diaphragm 15304 U ball bearing Distance collar Wheel balancer Tire Tube ) Rim ring bolt inal driven sprocket Fig. 25coum GF rensce . ™ CHASSIS A. Disassembly 1. Remove the rear brake rod. 2 Remove the rear brake panel stopper bolt to disconnect the brake stopper arm. Fig. 224. () Brake stopper arm © Stopper arm cushion rubber 2 faim nut @ Panel stopper bol ® Lock pin 3. Remove the both left and right mufflers. 4. Loosen the drive chain adjusting bolt on both sides, remove the cotter pin, and loosen the axle nut. 5, Push the wheel forward, and lift the chain off the driven sprocket. Remove the lock bolts, chain adjusting stoppers and pull the wheel rearward to remove the wheel and axle from the rear wheel. 6 Straighten the tongued washers and ‘ unscrew the four nu to remove the Fig, 225) Cotter pin driven sprocket Sa ba 7. Remove the rear wheel bearing retainer @ Lock with the bearing retainer remover, and Leck bs drive out the bearing from the hub. Note: ‘The bearing retainer has a left hand thread, Fig. 228) Driven sprocket 2 Tongued washer 3) Lock nut Fig. 27 D Bearing retainer remover 2 Bearing driverCourtesy Honda4Fun 5, CHASSIS wurwihondafour tom Atiichondadtun com 8. Remove the two cotter pins and washer from the brake shoe anchor posts, B. Inspection 1, Check rim runout and wobble. 2. Check rear axle shaft runout THe © ts dow @ Fin wasicr Sake shun ota 3. Check brake lining wear. ra * ae 4, Check brake drum wear. Check ball bearing wear. 6. Check for loose spokes, bending and da mage. Tighten, straighten or replace as necessary. Check tire on both inside and outside for cuts, bruises, and imbedded of nails Repair or replace as necessary Fig. 229 (1) Vernier caliper @ Brake shoe Fig. 231 (Dial gauge 2 Ball bearing% — : Fig. 233 () Cotter pin 2) Aale nut ) Adjusting: bolt ®) Lock nut Lock bolt poe ae — CHASSIS mbly in the reverse order of disassembly 2, Install the brake shoes on the brake panel Note: Use thread bearing retainer. Apply grease on the friction surfaces of the flange and wheel hub. ick cement when installing the 3. Mount the brake panel on the hub and the drive chain on the sprocket. Insert the wheel axle through the assembled wheel hub, and mount the wheel on the rear fork After completing the rea the a, Normal chain slack is 10~20mm 3/8~3/4 in) with a slight force. b. Loosen the drive chain with the adjusting bolt making sure the adjuster marks on mbly, adjust Jack of the drive chain. Je nut and adjust the both sides are in the same position when completed 5. Install the rear brake stopper arm, and adjust the height and play of the brake pedal a, Adjust the height of the pedal with the adjusting bolt. b, Adjust the free play of the pedal to 20~30 mm ("/,~1%/jgin) with the adjusting nut on the end of the brake rod,5. CHASSIS 3, STEERING The steel tube handle bar is mounted on the front fork top bridge with the handle bar holders. The top bridge is bolted to the front fork and steering stem. The steering stem is mounted on the frame head pipe ering handle Handle bar hol ing stem nut @ Steering stem washer 5) Fork top bridge © Steering head top nut weering head top cone race Seal at ® Steering top bull race W@ Steering head i Steering stem ering bottom ball race el ball ering bottom cone race 1 Steering head dust seal A. Disassembly 1. Unscrew two bolts to remove the master cylinder unit. 2, Disconnect the clutch cable at the clutch lever. 3. Remove the lighting switch and discon nect the throttle cable from the throttle grip pipe. 4, Remove the head light unit from the head light case and disconnect the wiring at the harness within the case. = 5. Unscrew four bolts, remove the handle [Bb 2) bar holders and disconnect the ‘wire PI» 297 @) Mir cylinder unit) Lighting switch harness = 238.) Upper handle bar holders @) Handle barHondagFun 78 Riubenlatwn nl famtenetimeen 5. CHASSIS 6 Unscrew the two mounting bolts and remove the speedometer and tachometer. 7. Unscrew the stem nut, remove the 8mm. bolts and the fork top bridge. Fig. 289° @) Fork top bridge @) Stem nut @) Fork top bolts @ 8mm bolts 8. Remove the front fork. 9. Unscrew the steering stem head nut with the stem wrench. 10, Remove the steering stem out the bottom Note: Steel balls will drop out, therefore, exercise care not to loose them, Fig. 240 @ Steering stem wrench Steering stem head nut B. Inspection 1, Check the handle bar for twisting and damage. a 2. Check the steering stem for twisting and cracking. 3. Check the steel balls for cracks and wear. 4. Check the cone race for wear. Fig. 241 @ Steel balie C. Reassembly 1. Mix the steel balls in grease and assem- ble 18 into the upper race and 19 into the lower cone. Install the steering stem into the head pipe being careful not to drop the steel balls 3. Assemble the top cone race and tighten the steering stem head nut. Note: Before assembly, wash the cone and ball Fig. 242 @) Steering stem wrench races, and steel balls. Mix the balls in new @ Steering stem head nut grease.4. Assemble the front fork 5. Assemble the front fork top bridge, and mount the speedometer and tachometer 6, Install the handle bar. Note: Align the punch marks on the handle bar to the parting surface of the holder. 7. Reconnect the electrical wiring, 8. Reconnect the clutch and throttle cables, and the brake hose to the master cylinder unit Note: + Make sure the cables and the electrical ings are free from binding when the handle is turned fully to both sides. + Adjust the play in the cables, Cluteh lever: 10.0~20.0mm (3 8~3/4in, at the end of the lever, Brake lever: 2~5mm (5/61~13,64in,) at the end of the lever, 4. FRONT SUSPENSION 5, CHASSIS iets 3 Pig. 248 @ Punch marks Fig. 244) Cluich cable @ Front brake hose 9) Throttle eable @ Wire harness 5) Fork top bridge ‘The front fork unit consist of a lightweight aluminium front fork bottom case with a dual action telescoping shock absorber oil damper. compression and 31mm (1,22in.) on extension strokes. Cushioning travel is 91mm (3.15in.) on @ Front fork bolt @ O-ring 3) Lock nut © Front fork pipe 5) Front suspension spring © Front fork boot @® Damper rod @ Snap ring © Oil seal Fig. 245 Front fork unit { Holder 4 Collar Front fork bottom case 4 Damper case Ww Axle holder 18 Plain washer f Spring washer NutHonda4Fun Fig. 216 Caliper mounting bolts 2) Adjusting screw ® Caliper set bolts @ Caliper B 5) Caliper A CHASSIS Disassembly Loosen the fork bolt, remove the drain plug and drain the damper oil Remove the front wheel Unscrew the three caliper mounting bolts and an adjusting screw, the caliper from the left front fork. and remove Unserew the 8x56mm and the 10x 35mm bolts, and pull the forks off the bottom. Unscrew the front fork bolt, loose from the piston rod lock nut, and remove the front fork spring and cushion spring seat Separate the front fork pipe and bottom case Unscrew the 8mm bottom case bolt using a special tool and remove the damper unit from the bottom case. Fig. 248 @ Snap ring Fig, 249 ® Front fork bolt 8mm bolt 2 Lock nut Damper unit ® Cushion spring seat @ Fork spring ® Soap ring @ Fork pipe 5) Oil seal Special tool © Bottom caseInspection Check the front suspension spring. Check the fork pipe and bottom case for damage or looseness. Check the oil seal for scratches and damage. Check for excessive clearance between the shock absorber piston and the cylinder. Reassembly Reassemble in the reverse order of disas- sembly, Assemble the damper unit and cushion spring with the lock nut, and install the unit into the bottom case. Install the front fork pipe. Install the snap ring. Apply thread lock cement around the thread of the piston rod, and tighten the lock nut. Next, tighten the fork bolt on the piston rod and screw the fork bolt into the fork pipe. Install the front fork unit through the steering stem and mount it with the 8 mm and 10mm bolt. Pad A Brake dise Nat © Caliper adjusting screw . Fig. 252 Oil seal drive weight @ Oil seal drive guide D 8mm setting bolt 2) 10mm setting bolt Fill the fork bottom case with 160cc (6.4 ozs) SAE 10 W-30 grade oil through the fork top bolt hole. 3. Adjust the front brake caliper. Adjust the clearance between brake disc and pad B to 0.15mm (0,006 in.) with the caliper adjusting screw.Courtesy of HondaFun 82 weewhondafour com ondattincom 5, CHA 5. REAR SUSPENSION The rear suspension is equipped with dual action telescoping shock absorbers. Rear fork is a swing arm type of tubular construction which provides greater rigidity. A. Disassembly 1, Remove the mufflers 2, Remove the rear wheel. 3, Remove the rear suspension mounting nut and bolt, and then remove the suspension from the frame and rear fork. 4. Compress the rear suspension spring using a special suspension compressor tool, and disassemble. Fig. 254 Rear fork pivot collar 2) Torque link arm ®) Rear fork pivot shaft @ Rear fork Rear suspension Suspension compressor tool 4) Spring seat stopper @ Rear suspension upper cover 8) Spring seat © Rear suspension spring Joint rubber Spring seat ® Joint @® Spring adjuster ® Nut @ Rear damper Rubber5, CHASSIS Remove the rear fork pivot nut and shaft, and separate the fork from the frame. B. Inspection 1. Check the rear suspension spring. 2. Check damper for cil leaks. 3. Inspect the damper upper case and rod for dent and bend. Make sure the oil damper operates smoothly in both direc: tions. 4. Inspect the damper case and stopper for damage and dent. 5. Check the clearance between the rear fork pivot bushing and shaft 6 Check the pivot shaft for bending. 7. Check the rear fork swing arm for bend -ing, twisting, and cracks C. Reassembly 1. Mount the rear brake arm stopper to the rear fork. 2. Apply grease on the fork pivot bushing and install the rear fork on the frame with the pivot shaft. 3. Mount the rear suspension between the frame and fork on both sides and tighten the cap nuts and bolts 4 Mount the rear wheel. Note: When the reassembly is completed, adjust the rear brake and the drive chain tension, Fig. 25 Courtesy of Honda4Fun werwhondstourceme /Winhondestincom — 83 D Rear fork @ Rear fork pi Pika \}— 135 33.5} 0 20 3 103) = ann Fig. 258 Rear shock abworber spring characteristic a ® Fig. 299° @ Micrometer @) Rear fork pivot shat Fig. 260 Inside dial gauge & Rear fork bushinga4 Courtesy of HondaaFun 5, CHASSIS 6. FRAME BODY A. Construction The double cradle frame is constructed of steel tubes and plates. The head pipe tion is of drawn tubing construction which provides high rigidity and strength for good handling at high riding speed. B, Disassembly 1. Position the fuel cock lever to ‘STOP’, disconnect the fuel tube from the fuel cock, and dismount the fuel tank from the frame 2, Remove the mufflers, and dismount the engine. 3, Remove the front wheel, and the front fork. 4. Remove the handle bar and the steering ae gctng fo stem from the frame. 2 Cotter pin 5. Remove the rear wheel, rear fork, and a eee rear fender. 6, Remove the seat, the tool tray, and the air cleaner element 7. Detach the electrical equipment. 8, To remove the main stand, unscrew the two mounting bolts, remove the cotter pin, and extract the main stand pivot pipe. Fig. 264 @ Mounting bolt 3) Cotter pin5. CHASSIS 9. Remove the top and bottom ball races from the steering head pipe. Note: Use a wooden drift to prevent damage when driving out the ball races, C. Inspection 1. Check the frame main unit for twisting, deformation, and cracks around the welded areas, and the pipes for bending and cracks. 2, Inspect the top and bottom races for scoring and wear. Check the head pipe for misalignment. Check seat cover for tears. Check fuel tank for leaks, fuel tubes for aging or damage, and fuel cock gasket and strainer cup O-ring for damage. Flush the tank interior with clean gosoline. 6. Remove dust from the air cleaner ele- ment by blowing compressed air from the inside, Check element for damage. Replace exhaust pipe gasket if damaged. ae D. Reassembly Install the main stand on the frame. 2, Install the rear fender and the electrical equipments on the frame, 3. Install the rear fork, rear cushion and rear wheel 4, Install the steering stem, front fork and front wheel. 5. Mount the air cleaner case, the battery, the seat, and the fuel tank Fig. 265 Fig. 266 Pig. 267 Courtesy DHondastun gs D Wooden drift 2) Ball race 3) Head pipe D Fuel strainer eup 2 Orring 4) Fuel strainer sereen ® 6mm cross screws 5 Buel cock body @ Fuel cock gasket ® Fuel cock lever 8) Cock lever spring ® Setting plate 8 6mm screw D) Air cleaner elementere ELECTRICAL | _— (980 eaenenenee Fig. 268 Complete electrical system diagram © Tachometer pilot lamp ) Speedometer pilot lamp 3) Head light © Position lamp (except USA type) Front brake stop switeh © Front winker lamp ® Emergency switch {Head light switch Starter switch @ High beam pilot lamp lamp: @ Speed warning lamp (except USA type) @® Winker switch ® Speed warning system (except USA type) 1 Contact bresker asembly 33 Battery & Horn & Main switch & Spark plog & AC generator 2% Oil pressure switch & Starting motor & Neutral switch & Rear brake stop switch 2 Fuse holder © Silicon rectifier ® Winker relay @ Magnetic switch & Voltage regulator & Tailfstop lamp @ Rear winker lampCourtesy HondagFun Wwentihondatourcomd /awhondashin-com 6, ELECTRICAL 2. IGNITION SYSTEM ® Hill Fig. 269 i) Spark plugs 8) Condensers ® Battery ® Ignition coils © Contact breaker ‘The ignition system consists of two ignition coils, two contact breakers, four spark plugs, an ignition switch and a battery. ‘The current from the battery flows through the primary winding of the ignition coil, and cireuit is completed by grounding through the contact breaker. Contact breaker is contained in the contact breaker housing at the right end of the crankshaft. There are two contact breakers which are 180° out of phase, One of the breakers furnishes high voltage current to spark plugs 1 and 4; the other breaker furnishes current to plugs 2 and 3. The contact breakers ignite the spark plugs in a firing sequence of 1, 2, 4 and 3 which is indicated on the high tension plug cords. Since no distributor is used, the construction is simple and the system is easy to service. SERVICE DATA Tgnition coil 8 point spark gap opening mm min, (0.27) Spark plug ‘Type (standard) NGK D-TES, | DENSO X22ES Plug gap 0.6~0,7 mm (0.023~0, 027 in.) Contact breaker Botnt gap 0.3~0,4 mm (0.012~0, 016 in.) Spring force {550850 g (1. 49~1. 87 Ibs) Condenser SS ee | Capacity 0,24 wF2-1095 Tnsulation resistance Over 10M (1, 000 megger) Sorgen ah shat 1,150) tart of advance (crankshaft 150 rpm Bull advance (oslahale opted 2, 80~2, 550 rpm Advance angle El6. ELECTRICAL Ignition Coil The ignition coil consists of a primary coil with 420 turns of copper wire wound around an iron core of laminated silicon steel sheets ‘A secondary coil with 13,000 turns of wire is wound on top of the primary coil. Each secondary coil has two high tension cords to two spark plugs A. Disassembly 1. Open the seat and remove the fuel tank. Disconnect the ignition coil leads. (yellow, blue and black/white) 3. Unscrew the two ignition coil mounting bolts, and separate the ignition coil from the frame. B. Inspection 1. Ignition coil continuity test Primary coils Check for continuity between the termi nals of the primary coil Right coil: yellow and black/white leads Left coil: blue and black/white leads Secondary coils Check for continuity between the termi nals of the high tension cords. If there is no continuity, the coil is open and must be replaced Honda4Fun Same wien 69 ® Fig. 270) Primary coil @ Iron core 3) Bobbin © Secondary ceil Primary terminal High tension cord ® High tension terminal Fig. 271 Fig. 272 Ignition coll continuity teatCourtesy HondaaFun wentihondstourcom( /Wawhondastincom 6, ELECTRICAL Fig. 278 Ignition coil performance test Fig. 274 Spark performance Ignition coil perfomance test Coil may test satisfactorily for continuity but it may not perform satisfactorily due to dete- ration from long use, therefore, perform- ance should be checked to determine its con- dition. Connect the service tester power cord to a 12V battery and ground the ground cable. Connect the ignition primary test lead to the tester and connect the opposite terminal ends to the primary terminals of the coil. Con- nect red test lead to the black terminal of the ignition coil and the white test lead to the yellow cord of the left coil (to the blue cord for the right coil). Position the selector knob to COIL TEST. Adjust the three point spark tester to the maximum distance spark is maintained and then measure this distance. The coil is satis- factory if the distance is greater than 7mm. (0.27 in.) ‘Note: Since a dual sparl ignition coil is used, note the spark condition. If the spark ap- pears as B in Fig. 274, the connection to the primary coil is reversed.Spark plug A. Removal 1, Remove any dirt from around the spark plug by using compressed air. 2 Remove the spark plugs with a plug wrench B. Inspection Inspect the spark plug for worn electrodes, excessive gap, fouled condition and damaged porcelain insulator. 1. Clean dirty spark plug with a plug cleaner or wire brush. 2, Measure the electrode gap with a feeler gauge and, if necessary, adjust to the specified gap Standard gap: 0,6~0.7 mm (0,023~ 0.027 in.) 3. Replace the spark plug if the porcelain insulator is damaged, or the gasket if it is damaged or distorted Standard spark plug: D-7ES (NGK), X22ES (DENSO) C. Reinstallation 1. Install the spark plugs in the reverse order of removal Torque: 1.5~2.0kg-m (11~14ft-Ibs) Note: 1. Exercise care not to drop the plug gasket. 2. Loose plug will not properly dissipate the heat and may result in engine mal- function. 6, ELECTRICAL Fig. 275 Fig, 276 D Spark plug D Feeler gauge HondaaFun 9, @ Spark plug cleanerCourtesy Honda4Fun 92 Wewtenlatounene /aeebensettimens , ELECTRICAL Contact Breaker and Condenser A. Disassembly 1. Remove the point cover. 2, Disconnect the leads (yellow, blue) at the connectors located at the center of the frame 3. Unscrew the 6mm bolt, remove the special washer, loosen the base plate mounting screws, and then remove the contact breaker assembly. B. . Inspection Special washer + For adjustment of the breaker point and tt ignition timing, refer to the section ©) Contact breaker plate “Maintenance Operations ”. + Condenser Measure the capacitance of the condenser using the service tester. Standard value: 0,22~0.26 F Note: The points should be open when testing. Fig. 278) Condenser Spark Advancer A. Di sembly 1. Remove the point cover and contact breaker assembly. 2 Remove the spark advancer from the spark advancer shaft. B. Inspection 1, Clean dust and foreign matters from friction surfaces, and assure that opera- tion is smooth Check spring tension, and advancer pin wear. Standard spring tension 680~850 gr. (1.43~1.87 bs) C. Reassembly 1, Install the dowel pin by aligning the hole. 2 Reassemble in the reverse order of re- moval. Fig. 280.) Spark advancer Crankshaft@ ELecteicaL Switching? pemncammcn 99 3. CHARGING SYSTEM ‘The charging system for the CB500 is made up of the exciter field 3-phase AC generator, rectifier, voltage regulator and the fuse. The generator consists of the field coil, stator coil and the rotor ; it does not contain slip rings or brushes, In order for the stator coil to produce a constant voltage, the current from the battery to produce the exciter field is regulated to very close limits by the dual contact regulator. The output from the generator is rectified by the silicon rectifier before being sent to recharge the battery. The generator performs two functions depending upon the charge condition of the battery. The electrical current from the battery flows through the switch and into the regulator. When the battery voltage is lower than normal (less than 13.5V at the battery terminal), the current flows through the upper contact and to the field coil. ‘The strength of the magnetic field is dependent upon the strength of the battery voltage. When the battery terminal voltage is 12V, the field coil current is 1.6A. This produces an output voltage of corres- ponding strength which is used to charge the battery. When the battery voltage exceeds approximately 14.5 V, the armature coil pulls the armature away from the upper contacts and closes the lower contacts to insert a 100 resistance into the field coil circuit. The current to the field coil is thus reduced to 0.7 A and, consequently, a lower voltage is produced by the generator, limiting the amount of charge to the battery. This function of inserting or removing the resistance into the generator field coil is performed by the voltage regulator in accordance with the charge condition of the battery. ——=———] a z . i @® | ® Fig. @ Silicon sctifer © Regulator © Rely coi ® Couple © Upper contact ® Stator oil 2) Batery 12V, 12 AH © Moving contact Field col @ Main switch Tower contact @ To indHondaaF Thendettmenen 6, ELECTRICAL Charging Test 1. Perform the test using ammeter and volt- meter. 2. The battery charge condition is deter- mined by measuring the specific gravity of the battery electrolyte. If the specific gravity is lower than 1.26 (at 20°C/68°F), recharge the battery so that the specific gravity is up to 1,26~1.28 (at 20°C/68°F), and then perform the following test. 3. Disconnect the battery cable from the @ Fig. 282 (i) Red/white lead ® Voltmeter terminal of the battery, and connect it 2 Ammeter © Battery to the ® side of the ammeter. Next, connect the © side of the ammeter to the © terminal of the battery. Connect the ® side of the voltmeter to the ® end of the battery cable, and ground the © side of the voltmeter. (Fig. 282) 4. Start the engine, operate the engine under both the NIGHT RIDING and DAY RIDING conditions and check to see if the measured values conform to those specified in the table below. If the values are less than those spi Note: ‘The charge condition of the battery may cause the charge current to vary slightly. ied, adjust the regulator. Fig. 283 ) A.C. Generator Ammeter ® Headlight low beam ® Silicon rectifier Main sveiteh Headlight high beam @ Voltage regulator Battery @ Volt meter ‘) Headlight switch — Engine RPM T 1,000 | 2,000 | 3,000 | 4,000 | 5,000 | 6,000 | 7,000 8,000 Charging current (A) Day riding 65 | 0 43) 10 | Lo) 08) 06 Night riding Battery terminal voltage (¥) w | i24|is2 | is | as | as | as | a5Courtesy HondagFun 9. 6, ELECTRICAL “Cwwrnontatourseng Siti deondetbon.con A.C. Generator Specifications ‘Type and maker | LD 110-01, Hitachi Output 150 W Battery voltage 12 Polarity ground Charging speed 1000-9000 rpm Weight 3kg (66 1bs) 28 @ Rotor puller @ Rotor A. Disassembly 1, Remove the generator cover and pull out ® ® @ the rotor using the rotor puller (special tool No. 07011-21601) ~ 2. Unscrew the three 6mm screws from a Kae i i = inside the generator cover and remove |/ aso 9 \ [OH ) the stator coil. } Zz. 3. Unscrew the three 6mm screws from =! tp ges the outside the generator cover and \ hg a= 4 remove the field coil. Fig. 285 @ Side cover @® Field coil B Generator cover @ Stator col B. Inspection ld coil continuity test Check continuity between the two leads (white, green) of the field coil using a tester. If there is continuity, the coil is satisfactory. Note: Test can also be performed without remov- ing the field coil. Standard resistance value: 4.90 +10% 2. Stator coil continuity test Check continuity between the three leads Fig, 286. Field coil (yellow) of the stator coil using a tester. If there is continuity throughout, the coil is satisfactory. Note: Test can also be performed without remov- ing the coil. Standard resistance value: 0.35.0 + 10% Fig. 287 Stator coil9 Sitheehien Send fameimatincen 6 ELECTRICAL Regulator The regulator is a dual contact type. If maintains a constant voltage by placing the resistance circuit into the field coil circuit when the generating voltage rises to a certain value, and cutting out the resistance circuit when’ the voltage drops below a set limit A. Disassembly 1, Disconnect the leads at the connectors and unscrew the two 6mm_ regulator mounting bolts. 2. Unscrew’ the two screws and remove the S2@8 6@ Fig. 257 regulator cover. ) Point gap @ Voltage adjusting screw ) Upper contact a Lock nut B. Inspection and Adjustment ») Armature 8 Coil Regulating voltage adjustment @ Core gap # Point gap adjusting se 1. To adjust for low charge current or low gs Bes ee Cine cite battery voltage, loosen’ the lock nut on @ Yoke a Lower contact the voltage adjusting sc and turn the adjusting screw clockwise, When the regulator is set too high, turn the adjust- ing screw counterclockwise. 2. Upon completing adjustment, recheck regulator performance after installation. ® Adjusting spring Core gap adjustment Measure the core gap with a feeler gauge. If it requires adjustment, loosen the core gap adjusting screw and move the point body up or down Standard core gap value 0.6~1.0 mm (0.02~0.40 in., Point gap adjustment Measure the point gep with a f If it requi adjusting screw and move the lower point up Fig. 289 G) Regulator or down. Standard point gap value 0.2 mm (0.008 Note: If the points are pitied or fouled, polish with a 2500~600 emery paper atage adjusting screw Fig. 291 Core gap fock nut Point gap D Core gap adjusting screw 8) Point pap adjusting scr 3) Lower point8. ELECTRICAL ilicon Rectifier Inspection The condition of the silicon rectifier is tested by disconnecting the electrical connections and testing the rectifying funetion in both the normal and reverse directions. Continuity in the normal direction only indicates good condition. Continuity in both direction indi- cates a defective rectifier. ote: 1. Do not use a megger for the test as the high voltage will damage the silicon diodes. 2. Observe the polarity of the battery. Con- necting the battery terminals in reverse will shorten the life of the battery as well as causing a large current to flow through the electrical system, causing damage to the si n rectifier, and also destroying the wire harness. Do not operate the generator at a high RPM with the “P” terminal (red/white cord from the magnetic switch) of the icon rectifier disconnected. The high voltage generated may damage the silicon rectifier. 4. When charging the battery mounted on the motoreyele from an external source with high charge rate such as a “quick charge”, the wiring to the silicon rectifier should be disconnected at the coupler to prevent damage. Courtesy mtcatattan 97 Fig. 292 Silicon rectifier inspeetion D, @.@ Yellow ® Yellow/White @ GreenCourtesy Honda4Fun 98 wwwhemistoursend /amnaendtmcem 6, ELECTRICAL 4, STARTING SYSTEM The starter is a device which converts the electrical energy of the battery to the mechnical energy to crank the engine for starting. The starting circuit consists of a push button switch mounted on the right side of the handle bar which, when the starter button is pressed, energizes the starter magnetic switch and closes the contacts of the starter circuit. This permits approximately 120A of current to flow from the battery to the starting motor, which then rotates the engine to perform the starting. Fig. 291 Starting Circuit D Brush ©) Field coil Starter button 2) Armature @ Starter magnetic switeh @ Battery 3) Starting motor @ Eleetromagnet a Plunger @ Pole ® Ignition awiteh Fig. 295 Starting motor installation } Starting motor @ Starter reduction gearCourtesy HondaaFun 6. ELECTRICAL wwwhondatourcom( /iawhondoatuncom 99 Starting Motor ‘The starting motor is mounted on the crank- ease behind the cylinder and drives the ankshaft through the starting clutch Specifications Rated voltage 12V Rated output o6 KW Rated operation Continuous for 30 seconds Without load | With load Voltage BV nv Amperage 35 A 20 A ° 0: 42 kg-em Torque Ries i 2200 1 Revolution 00 rpm | _$200Fpm Fig. 296 Starting motor disassembly drawing A. Disassembly 1. Disconnect the starting motor cable at the magnetic switch. 2. Remove the starting motor cover, left crankease cover and unscrew the two 6mm starting motor mounting bolts. 3, Starting motor can now be pulled out 4. Unscrew the two 6mm screws and re- move the starting motor side cover. ng motor cable Fig. 298 Starting motor @ 6mm boltsHonda4Fun D Carbon brushes Springs 3 Commutator Fig. 299 Fig. 901 Armature coil inspection B. Thame 6 ELECTRICAL Inspection Carbon brush inspection Worn carbon brush, pitted or rough co tact surface and weakened brush spring will cause starting difficulty, therefore, they should be replaced, Commutator cleaning Dirty commutator will give poor starting motor performance. Surface of the commutator should be polished with a fine grade emery paper and completely washed before reassembly. Stator coil inspection Check continuity between the brush wired to the stator coil and the starting motor cable, Lack of continuity indicates an open stator coil and should be replaced. Armature coil inspection A grounded armature coil will render the starting motor inoperative. Perform a continuity test between the commutator and the core. A continuity condition indicates a grounded stator coil and should be replaced,6, ELECTRICAL ‘srw hontefour omy Starter Magnetic Switch ‘The starting motor requires a large current of approximately 100 A to operate. To minimize resistance, a large cable is used for wiring, also, a switch with heavy duty contacts is required. Sparking across the contacts will result, aswell as resistance depending upon the contact pressure, when the contacts are opened suddenly to shut off the flow of large current. To cope with these conditions, a magnetic switch is used separately which is operated electrically by a small current through a push button starter switch. Inspection 1. Primary coil continuity test. If there is no continuity, the primary coil is open, + If a clicking noise is heard when a 12V battery is connected to the two leads of the coil, the primary coil is satisfactory. 2, After long use, the magnetic switch con- tacts will become pitted or burnt from the large current which flows across it, and gradually build up resistance which may prevent the current from flowing. Connect 12-V to the primary coil leads of the magnetic switch. If there is no continuity across the switch contacts, the switch is defective. Courtesy HondaaFun Tiehendettencom 101 @89966680 ® Fig. 302 1D Stopper Contact bolt @ Stopper holder i Case @) Washer i Contact plate © Roller A i Yoke Contact spring 4 Coil bobbin © Flat washer {8 Coil complete Phunger holder Plunger shaft ® Plunger Return spring Fig. 303 Primary coil continuity testHonda4Fun Fig. 300 Bye level @ Blectolyte @ Hydrometer ® 1 2030 a 30808086108 D Specific gravity 2) Relation between specific gravity ') Residual charge (% hate ~~ Fig. 906 (Sediment) Plates 2) Battery case Fig. 307 Charger hook-up Tavendethincom 6 ELECTRICAL Battery A. Specification Type NIZA-4Ad Voltage wv Capacity 12AH B, Specific gravity measurement Battery electrolyte is measured with a bulb type hydrometer. When the specific gravity is below 1200 (at 20°C), the battery should be recharged. When making a reading, the hydrometer should be held. vertical with the electrolyte liquid level, held at the eye level and the value on the floating scale read at point where the liquid separates from the stem of the float C. Inspection and replenishment 1, Electrolyte in each cell of the battery should be inspected every half month to a month, and distilled water added to bring the level to the upper mark when- ever the electrolyte level is below the level mark 2, Whenever there is rapid lowering of the electrolyte level, the charging system should be inspected Periodically measure the specific gravity. After adding distilled water, allow the battery to be charged and the electrolyte sufficiently agitated before making the surement, P ary battery troubles are due to cor- rosion around the connetors and terminals causing poor contact, separation of the battery paste, and sulfation (battery which is lefi in a discharged condition for a long period will have lead sulfate formed on the plates and recharging will not restore it to its original condition), there. fore, the inspection should be performed periodically and thoroughly. Note: When sediment are formed at the bottom as shown in the figure, the battery should ‘be replaced. D. Battery charging (Caution) 1. Refrain from charging the battery at a fast rate (quick charge) as it shortens battery life. When rapid charging is necessary, limit the charging rate to maxi- mum of 20A. Hydrogen gas is charging proces away. 3. After battery charging is completed, wash the battery with water to remove spilled electrolyte, and apply grease to the term nals. generated during the therefore, keep fire6. ELECTRICAL ELECTRICAL EQUIPMENTS Main switch inspection With the switch in both ON and OFF positions check to see that the continuity conditions in the chart below are satisfied The switch is defective if there is no continuity where specified, or if there is continuity where not specified. BAT 1G | Th Th Color of Brown coal Red | Black BF) Brown OFF Key position Front stop switch inspection Apply tester lead probes to the terminals of the front stop switch cords (black, green/yellow), operate brake lever and check for continuity Take into consideration the lever play 2~5mm (0.08~0.2 in. The stop light should come on when the brake lever travels beyond the play in the lever. Rear stop switch inspection After making sure that the stop switch spring is disconnected, apply tester lead probes to the switch terminals (green, yellow, black and check for continuity, When the brake pedal is depressed 20mm (0.8in,) at the front end of the pedal, the stop light should come cords) on at this point. Adjustment. If the stop light is late in coming on, turn the adjuster nut clockwise, and if too early, turn counterclockwise. Horn Inspection Check for continuity across the lead terminals Alternate method is to connect the horn toa fully charged 12 V battery and check its operation. horn Courtesy HondaaFun 103 ® Brown ® Red Fig. 09 Front stop switch inspection D Front stop switch Fig. $11 Horn continuity testFig. 312 @ Horn button @ Light green cord Pig. 313 @) Winker switch @ Light blue cord © Gray cord @ Orange cord Fig. 314 @ Lighting ewiteh @ Black cord @ Blue cord @ Brown/white cord © White cord Horn button inspection With the tester lead probes contact the light green cord terminal within the head light case and the the handle bar, and then press the horn button to check for If continuity exists, the horn button is satisfactory. Winker switch inspection. Disconnect the winker switch wiring within the head light case. Check con- tinuity between the gray cord terminal and orange cord terminal (left winker), and between the gray cord terminal and light blue cord terminal (right winker) respectively of the winker switch. Con- tinuity for the respective tests should exist according to the switch connections shown in the table below. Knob ae R ot OFF (center) L o——9 . Lighting switch inspection. Inspect for broken wire and defective contact between the respective switch cords, using a tester. Continuity between the different cords should exist in accord- ance with the switching position table shown below, — If continuity exists where not indicated the switch is defective. TC 5 1G | HB ) | hb Cord color | iS, HB. Browns wit. white a] o+-0-Lo on [P/O O L| o- -o——OEmergency switch and starter switch in- speetion Inspect for broken wire and defective contact between the respective switch cords, Continuity between the different cords should exist in accordance with the switching position table shown below. If continuity exist where not indicated, the switch is defective Courtesy & ELECTRICAL ww bemdetoursee HondaaFun uhenatine — 105 Emergency switch Cord colar Black | Black/white oN OFF ch D Black/white Starter switch Card color Yellow/red ON OFF Oil pressure switch inspection Lubricating oil is supplied under pressure of 4~6kg/em® (56.8~85.3 Ibs/in.:) by the oil pump to various parts of engine. When the oil pressure drops, the oil supply becomes insufficient, ‘The oil system is designed so that when the oil pressure drops below 0.5kg/em? (7 Ibs in), the oil pressure switch operates and the warning lamp comes on. Check the oil pressure switch for conti. nuity without starting the engine and with the main switch on. If there is continuity, the switch is satisfactory, It is normal for the warning lamp to go out when the engine is started If the warning lamp does not go out after starting, and the pressure switch is satisfactory, the oil system should be inspected for trouble. Fig. 316 Fig. 317 D Starter switch 3) Yellow/red D Oil pressure switchCourtesy HondagFun 106. wewbentstournd ARRnenadtince 6 ELECTRICAL 10, Neutral switch inspection The neutral switch is mounted on the left side of the upper crankcase. When the transmission is in neutral, the switch be- comes grounded and the neutral pilot lamp comes on. Position the transmission in neutral, remove the left crankcase cover and check the continuity of the neutral switch. The switch is satisfactory if there is continuity. Fig. $18 Neutral switch inspection @ Newtral switch. TROUBLE SHOOTING Courtesy HondaaFun ENGINE Trouble Probable Causes Engine does not start 1. Excessive wear of piston ring or cylinder | Replace 2 Seized valve in valve guide Replace &. Seized piston Replace 4. Faulty valve timing Adjust 5. Low or lack of compression prasure Lap the valve to obtain good valve seating + Pressure leak for replace 5, Blown out cylinder head gasket Replace ‘Overheatin White exhaust smoke | Black exhaust smoke 6. Warped gasketing surface of the cylinder 1. Incorrect tappet clearance 2. Low or lack of compression pressure Excensive valve guide clearance 1. Valve sticking open 2. Incorrect seating of valve Weal or broken valve spring . Faulty yalve timing Blown out eylinder head gasket Excessive wear of cylinder and piston Worn, weak or broken piston ring Loose spark plug, 1, Heavy carbon deposit on chamber and piston head ‘Lean fuel mixture combust 3. Retarded ignition timing Low oi level. poor quality |. Extended operation in low gear Incorrect seating of inlet valve Faulty valve timing &. Incorrect timing 4. Excessive spark plug gap 5. Improper fuel 1, Excessive wear of cylinder and piston 2, Overfiled engine oil 3. Excessively high oil pressure 4, Poor quality oil Rich fuel mixtare Repair or replace Adjust to standard value Repair Replace valve and guide Replace Lap valve Replace Cheek valve 1 Replace Replace Replace Retighten Remove carbon Adjust the carbo Adjust ignition timing ‘Add good grade oil \Glaak Ga le aay | Adjust Adjust Adjust the gap to 0.024~0.028 in (0.6~0.7 mm) Replace Replace the piston ‘Adjust the wil level Cheek the breather Replace with good quality oil Adjust the carburetorHondaaFun 7. TROUBLE SHOOTING ‘Trouble Difficult gear shifting Excessive high gear noise Gear slip out Clutch slippage Poor eluteh ‘engagement, Pedal does not return Kick starter wear does not rotate Engine does not start Poor engine idling ‘proper run ning of engine Probable Improper clutch disengagement Damaged gear or foreign object lodged in the gear Gear shift fork inoperative Incorrect operation of the gear shift drum stopper and change pedal Mainshaft and countershaft out of alignment High oil viscosity Excessive gear backlash a Worn main and countershaft bearing Worn fingers on gear shift fork Worn gear dog hole Worn spline No play in the clutch lever Weak or none uniform clutch pressure plate spring Worn or glazed friction dise Excessive play of clutch lever Warped friction dise Warped pressure plate Bent main shaft Faulty return spring Unhook return spring Excesive wear of kick starter pawl Carburetor 1, Choke fully open 2. Carburetor air serew improperly set &. Air leaking into the cylinder head 4, Clogged carburetor slow jet 5, Clogged fuel valve or piping 6. Clogged vent hole in the fuel tank cap 7. No fuel in the tank Carburetor 1. Clogged or loose carburetor slow jet 2. Improper float level 3. Incorrect air serew adjustment 4, Carburetor linkage mulfunetion 5, Air leaks Carburetor 1 Jet size too small Improper flat level Clogged carburetor main jet Carburetor linkage mulfunction Air leaks Remedies Adjust the clutch Replace the defective parts Repair or replace Repair of replace Repair or replace Change the oil Repair or replace Repair or replace Replace Replace Replace Adjust the clutch lever Replace the weak spring Replace ‘Adjust clutch lever play Replace Replace Replace Replace Hook return spring Replace Close choke Adjust air serew Retighten carburetor connecting tube Check, clean and retighten Disassemble and clean Disassemble and clean Fill tank with gasoline Cheek, clean and retighten Adjust Adjust Adjust Tighten all air passage connection Replace with larger size jet Adjust Clean and retighten Adjust Tighten all air passage connectionCourtesy off )HondaéFun 7. TROUBLE SHOOTING " 109 CHASSIS Trouble Probable Causes ‘Remedien Heavy steering 1. Steering stem excessively tightened Looten the steering stem aut 2. Damaged steering stem steet balls Replace 3. Bent steering Replace 4, Low front tire pressure Add air to the specified pressure of 18ka/em* (256 psi) Front and rear 1, Loose steering stem mounting bolt Retorgue wheel wobble 2 Worn front and rear wheel bearings Replace bearing. 3. Front or rear wheel runout or distorted Repair or replace 4, Loose spoke Retorque 5. Defective tire Replace Soft suspension 1, Loss of spring tension Replace 2 Excessive load Hard 1, Ineffective front fork damper Repair suspension 2. Ineffective rear damper Replace Suspension 1. Front case or rear damper rubbing Tnwpect cushion spring and ease noise 2 Interference between cushion case and Repair or replace Defective brake spring Faulty fork stopper rubber Insufficient front fork cil Front brake duid “Insufficent brake id + Air in the brake system + Worn brake pad + Worn piston + Worn or distorted front brake dise + Brake lever out of adjustment 2, Rear brake + Worn brake lining, + Worn brake shoe or poor contacts + Worn brake cam + Wet brake from water or oil + Worn brake shaft + Brake pedal out of adjustment Replace ‘Add damper oil Add brake uid Bleed brake system Replace pad Replace Replace disc Readjust Replace Replace Replace Clean Replace ReadjustCourtesy HondaéFun ml ice 7 TROUBLE SHOOTING ELECTRICAL Troubles Probable eauses Remedies Engine does not 1. Battery —_ tL = Discard Recharge or replace + Poor contact of battery terminals 2 Main switch + Open or shorted circuit, disconnected connections + Poor contact between main switch wire and wire harness 3 Ugnition coil + Improperly insulated high tension coil + Open or shorted cirewit in ignition coil 4. Contact breaker + Open circuit in the primary coil + Dirty ground point with oil or dust gap out of adjustment + Improperly charged condenser Starting motor does not operate, Defective battery Poor contact of magnetic switch Poor contact of starting motor earbon brush, Horn + Cracked diaphragm Horn button + Poor growuding Wiring | + Poor contact 4. Adjusting screw + Out of adjustment Tail light and 1, Fuse hhead light + Blown fuse or hurnt bulb filament inoperative 2. Bulb + Burnt bulb filament & Switch + Poor contact of lighting switch 4. Wiring light 1. Bulb inoperative + Burnt or broken bulb filament Front and tail stop light switeh + Malfunction of switeh 3. Wiring Poor contact of leads Bulb oe 2 Wiring + Blinks too fast: bulb with unsitable ~ Blinks t00 dows burst oe broken balls | ioe 3. Defective relay l Winker lamp 1, improperly Repair Repair Repair Replace Replace Repair Clean, Readjust Replace Charge or replace Repair or replace Repair or replace Replace Repair Repair Readjoat Replace Rendjust Readjust Replace Readjust Readjust Replace Replace Replacecourtesy off HondagFun 7. TROUBLE SHOOTING. mM Trouble Probable causes Remedies Winker lamp |i. Winker lamp swith = inoperative + Poor contact of winker relay Replace + Open circuit in winker relay coil Replace 2 Bulb + Bulb wattage is smaller than rated wattage | Replace 3. Relay + Poor contact of winker relay Replace + Improperly connected leads Replace No charging 1. Broken wire or shorted, Joose connection | Repair or replace 2. Faulty coil due to short or grounding | Replace 3, Faulty or shorted silicon diode Replace 4. Broken or shorted lead wire at regulator | Repair or replace 5. Regulator voltage at no load is too low | Readjust Insufficient charging 1. Wiring + Broken wire, inter connection 2. Generator + Shorting across layer in the field coil (resistance indicated in continuity test) + Shorting across layer in stator evil ittent shorting or loose + Open circuit in one of the stator coil + Faulty or shorted silicon diode 3. Regulator + Voltage below specified value at no load + Dirty of pitted points = Coil or resistor internally shorted 4. Battery + Low electrolyte level Repair, retighten Replace Replace Replace Replace | Readjust Polish or replace Replace Add distilled water vibration or broken wire making. partial contact 2. Generator + Layer short (intermittent shorting) 3. Generator Intermittent open cireuit in the coil ‘Improperly adjusted voltage + Defective key switch + Dirty points + Defective battery plates Replace 1, Wiring charging P terminal circuit and F terminal circuit Repair shorted resulting in aplit wound generator 2 Battery Internal short Replace 3, Regulator + Excessive voltage at no load voltage | Repair “Improper grounding: Provide proper ground + Broken coil lead wire Repair, replace Unstable 1 Wiring charging + Bare wire shorting intermittently under | Repair or replace Repair or replace Repair or replace Readjust Replace CleanCourtesy of HondadFun 2 7. TROUBLE SHOOTING Trouble Probable causes ‘Remedies Self discharge 1. Dirty contact areas and case 1. Always maintain the exterior clean. Battery discharges in ad- | 2. Contaminated electrolyte orelectrolyte | 2 Handle the replenishing electrolyte dition to that caused by the connected load. C. Large discharge rate Specific gravity gradually lowers and around 1.100 (S.G), the winker and hhorn no longer function High char te electrolyte level rops rapidly but the charge is always main- tained at 100% and the condition appears satis- factory. (Specific gravity over 1.260) Electrolyte evaporates peRP Sulfation The electrode plates are covered with white layer fF in spot ‘Specific gravity drop excessively concentrated. ‘The fuse and the wiring aresatisfactory, ‘but loads such as winker and horn do ‘not function. In this condition the motoreycle will ‘operate but with long use, both @ and © plates will react with the sul- furie acid and form lead sulfide de- posits, (sulfation) making it impossible to recharge. The deposit will heavily accumulate at the bottom and will cause internal shorting and damage the battery. Shorted. Insuficient charging. Distilled water overfilled, Contaminated electrolyte. Charging rate is too small or else | 1 excessively large. ‘The specific gravity or the mixture of the electrolyte is improper. Battery left in a discharge condition for a long period. (left with the switch turned on). Expoted to excessive vibration due to improper insulation, with care, When the specific gravity falls below 1,200 (20°C: 68°F), the battery should be recharged immediately When the battery frequently becomes discharged while operating at normal speed, check the generator for proper output. Af the battery discharges under nor- smal charge output, it is an indica of overloading, remove some of the ‘excess load. ‘Check to assure proper charging rate. “Check specific gravity measurement, 2, If the addition of distilled water causes drop in specific gravity, add sulfuric ‘acid and adjust to proper value. When motorcycle is in storage, the battery should be recharged once a month even though the motorcycle is not used. Check the electrolyte periodically and always maintain the proper level Ina lightly discharged condition, perform recharging and discharging several times by starting the engine 2 a ‘Spark plug electrode — overheated or burnt 2 Damage Spark plug overtorqued. iguide and valve stem. Use of hot spark plug. Engine overheating. Improper ignition timing. ‘Loose spark plug or damaged spark plug hole thread. Too lean a fuel mixture, 5. Motorcycle stored during cold séason may be sufficient, with battery connected. Spark plug electrode 1. Too rich a fuel, ‘Adjust carburetor. coated with carbon 2. Excessive idle speed. Adjust idle speed. deposit 3. Poor quality gasoline. Use good quality gasoline 4. Clogged air cleaner. Service the air cleaner. 5. Use of cold spark plug, Use proper heat range plug. ‘Spark plug electrode 1, Worn piston ring. Replace piston ring. fouled with oil 2, Worn piston and cylinder, Replace piston or cylinder. 3, Excessive clearance between valve | Replace valve guide or valve. ‘Use proper heat range plug. Readjust ignition timing, Retighten plug or replace cylinder head. Adjust carburetor. Replace with a new spark plug.Courtesy MAINTENANCE SCHEDULE The following list indicates the items and time interval of preventive maintenance by which the best riding conditions are assured, The operating procedures for individual items are explained in the section of MAINTENANCE OPERATIONS. ‘The “months” in the list represents the lapse of months since the purchase of a new motorcycle and the “mileage” is a reading on the odometer, After 24 months or 12,000miles (20,000km), 8. PERIODICAL MAINTENANC HondaaFun described in the column of 6, 12, 18 and 24 months at every 6 months or 3,000 miles (5, 000 km) intervals. The following parts should be severely in- spected at the time of 24 months garage service. * Front brake hose Brake cable Front brake stop switch Brake master cylinder primary and sec- ondary caps Brake disc caliper piston seal * Carburetor rubber caps . repeatedly perform all items which are * Fuel lines Mile 600 | 3,000 6,000 9,000 12, 000 Fuge Retest ee: Ea | 1,000 | S000 | 10000 15/000, 20,000 Engine Caneel 5 aa =| Change oil filter element Bee ee “4 ‘lasn ol recs Bie 3 a Service park plage o|o 13 a1 Service contact breaker points | 0 > O 10 Adjust ignition. timing o | ° < ° 10 Check ignition primary and secondary cables O 5 9 ‘Adjust valve tappet clecrancta Kk. 6 7 “Adjet com chain of o|o| 0 2 Service air leaner o | 90 6 ‘Adj carburetors a | o |< 8 Check itvotte valve operation 5 0 Cath Adjust clutch O QO — Battery Service battery eo] a Fock ayatem Clean fuel valve wainer o. « Check fuel tank and fuel lines O ° GgCourtesy HondaaFun 6 12 690 3,000 6,000 4 8 PERIODICAL MAINTENANCE Moneis oF wa, WHERE | Month Mile Km Service required 1,000 5,000 10,000 Steering and Front Suspension 1 18 9,000 000 Page Reference Check and adjust brake pedal Check rear brake shoe linings Check rear brake stopper arm Check seeing, head bearings 78 Check steering handle lock 78 Check handle bar holder - Check front fark top plate - Check front fork bottom ease n Change front fork oll 7 Rear suspension Grease sear fork z Check rear fork @ Check rear suapension mounting bolts 8 Wheels and Brakes Check Front and rear wheel spokes ro CCheck front and rear whee! rims and hubs « Check front and rear wheels, bearings and axles a Check front and rear tires = Check front brake caliper and pad linings 7 Check front brake lines u Check brake fluid level u Cheek frame Check exhaust system Check side stand Service and adjust final drive chain Check final drive and driven sprockets Frame and Final Drive 16 Lights ‘and Accessories Check lights and switches ‘Check. horn Check speedometer and tachometerA. Specifications DIMENSION FRAME ENGINE Courtesy off HondasFun 9. TECHNICAL DATA Trem Overall Length Overall Width Overall Height Whee! Base Seat Height Foot Pea Height Ground Clearance Dey Weight Type Suspension, Travel R. Suspension, Travel F, Tire Size, Type R, Tire Size, Type F. Brake, Lining Area R. Brake, Lining Area Fuel Capacity Fuel Reserve Capacity Caster Angle Trail Length Front Fork Oil Capacity Type Cylinder Arrangement Bore and Stroke Displacement Compression Ratio Carburetor, Venturi Dia, Valve Train Maximum Horsepawer Maximum Torque Oil Capacity Lubrication System English 0in 325i 0in. 55 Bin 1,405 mm SL. Tin 805 mm 124i 315 mm Sin 165 mm 403.5 1h 18 Double cradle tubular steel Telescopic fork, travel 4.8in, 121mm Swing arm, travel $n 745i 8. 15-19 (PR) Rib tire, tive air pressure 25.6psi | 1. 8kg/em* 3. 50-18 (4PR) Block tir, tire air pressure 28.5 xi | 2 Okgiem® Die brake, Tining ren 82 36 jn? 288. Sem Internal expanding shoe, lining area 26, 28 in? 3.7 US.gal. 3.1 Imp. gal L6US gal 6¢ tin, 105 mam 54am 160 ce “Aic-ooled, 4atroke, OLLC. engine cylinder in-line 56050, 6mm 498 ce a0 Four, piston valve, wm dia, Chain drive overhead camshaft 50 BHP (SAE)/9, 000 rpm 304 Ist/7, 500 rpm 4.2kg-m/7, 500 rpm S2US.qt, 26Imp. at ali Forced pressure and wet sump)HondaaFun Courtesy rrgsmondotoursom Tem English Air Filtration Valve Tappet Clearance Engine weight 152 1b, "Air Screw Opening Tale Speed | ctuten ENGINE Transmission "Primary Reduction Gear Ratio 1 DRIVE TRAIN Final Reduction [Gear Shift Pattern | Tanition | Starting System | Alternator Battery Capacity Spark Plug Headli | Turn Signal light | Specdometer Light | Tachometer Light | "Neutral Indicator Light “Turn Signal Indicator Light | High Beam Indicator Light IN: 0,002, EX: 0,003 in. 2,000, drive sprocket 17, driven sprocket $47 Electrical motor and kick pedal Three phase A.C. 12 V-0.2 KW/ 9. TECHNICAL DATA Metric Paper element IN: 0,05, EX: 0,08 mm Goke 151/8 turns 1,000 rpm Wet, multiplate S-speed, constant mesh 000 2.353 1. 698 1.269 1.036 0.900 Left foot return type Battery and ignition coil 000 rpm 12,V-40 W/50 W 12V- 7 Wea W 12.V-25 W/2s W wV-3W wv-3W 12V-3W nV-3W 12V-3WCourtesy HondaaFun 9. TECHNICAL pt nn — 7 mm (in.) B. Service Data Them | Standard value | “a 4, ENGINE Clee beet = lin mm (in.) Tiem | Standard value /Serviceabe limit Tem | Standard value ya] BAG” SHEN stas)| 9585. 4075) bg ee ee ee tem height (1 SSB5—1a 10) 49 (1-998) Quer isewanske Runout — 0.1 (0.004 ) tem | Standard value |Serviceable limit | Cylinder 56~56. 01 ae Ga | act | sete Trem | Standard value Serviceable limit Piston dia. | GPogg—o'ops) 55-85 (2.198) [Piston pinhole —7 15, 08 (0. 593) Ttem Standard value |Serviceable limit Piston ring | 0,15~0.95, : end gap (0.008~0.013) | %7 (0.027) GEE SE ER Standard value | Service Timi] 0, 040~0. 075 Top sing {(o,oo1s~o. go29)) 18 (0.007) 0,.025~0. 06, ‘ Second ring |(o°sq95-0, 0023), 0-15 (0.005) 0, 000~0. 085 it sing contac, 25 (0-008) Tem | Standard value |Serviceable limi Jing groove| 15.002~15.008 Replace if over fBsranoe. (0S8068~0.5087) 15080 (0.6007) (dint Loading 100, 54~111. $7 Ibsft) reference) Inner 28,2 mm/19, 1~21. 1 kg, {(0:9in/ 421, 15~464, 35 Ibs) elutes ach — 0.3 (0.011) Oil pump Standard value Serviccale Kil] Tier and outer rotor clearance | az ereed | aes (ain) 0.35 (0.013) Ttem Standard value | Serviceable Faget 30.19 | 80(01 Sankt aie TS ing 21.0025) 30.50.20) re length 3 S433 bg at mm 2a (227, 8A~ 238, 6 seength | (7h 0.00%) Standard vale | Serviceable limi 39, 975~39. 95 drum O.D, (1, 6738~1. 5728) | 39.9 (1.5709) ‘Shift fork | 40.00~40, 025 LD. |(a.stas—1.s267)| 40-075 (1.5787) Standard value Tnlet 0, 010~0, 095, ‘Valve stem —(0-00038~0. 00197) (0.0031) _ clearance) Exhaust (r030~0.050 0.10 (@-0011~0: 0018) | (0.0030) i Inlet 5 450~8. 465 Valve stem | (0.2145~0.2150) diameter Exhaust 5, 430~5, 445 (0.2137~0. 2142) Valve face ass 0.05 runout (0-008) Gear HIE Standard value | Serviceable limit Ci 5.93~6.00 | 5.60 re (0. 233~0, 236) | (0. 220) i 493~50 ) 4.60 bhi | (@-194~0. 197) | (0. 181) Tem | Standard value | Servieable limit ‘Craeahafe - 0.020~0, 046 Journal "a poord=. coax) 080 (0.0031) Runout 0.05 (0.0019) Seaceal —_ 0.05 (0.0019) land taperCourtesy Honda4Fun 11g Mittondetourcomd /Amichondatncon 9, TECHNICAL DATA ‘gears backlash —(0.0017~0, 0051) (0, 0078) 4th and Sth 0.046~0.140 0,2 gears backlash (0, 0018~0, 0055), (0 5, CHASSIS: ‘Wheel | Sandird value |Servcsble lini Rim wobble | 0.5 (0. 020) 2.0 (0,08) bone 0.5(0.020) | 2.00.08) ft juheel beatiPa 0, 07 (0.028) 0.1 (0, 004) falal Uncato FHR_aomry_|2-08 (0.02) Caliper Calige ag. 3~38. 20 gpinder (1 S011, 8099) Caliper ay 11595 48 Pion ag (13061 819) Front brake | Standard value Serviceable limit 38. 215(1, 504) 38. 105,1. 500) Front brake | Standard value Master 14,0~14. 043. eylinder (0. 8511~0, 5528) eee, 13, 957~13, 984 (0. 5494~0. 5505) Serviceable limit 14.085 (0. 533) 18, 940(0, 549) Rim runout, (vertical and) 90-08 Bde) ‘Wheel | Standard value |Serviceable limit 2.0 (0.08) Tem Standard value Serviceable limit Ttem ‘Standard value aeons Connecting = a Dine trueness — | 0.30.01 oe (0. 00072~0, 00181) 9-08 (0.0031) Caliper and elearance Sie 0.11(0, 004 mam (in) Master eylinder Tem | Standard value Serviceable limit se per = Connecting 0. 12~0.27 0 | pd side (0, 0047~0. 0106) (0.0138) mm (in) Rear axle shaft) Standard value | Seer "Tem | Standard value |Sevibleini Bacein | Reon, Connecting | 15.016~15.034 | 15.07 so1t=0. 5018) [clearance (otha (6. 6990) Brake lining Standard value |Serviceable limit} er Thickness 2 = Tt ae TR Thicke 5.0 0.200) 0 (0,080) 1st, 2nd, ed 0, 0840.99 | 0,2 Brake Drum| Standard value |Serviceable limit Tide din €72,8180.2 x. 07.125) Tien] Sanderd vise [Soran Axial, TIR 0.070.002) | 0.1(0. 008) Radial, TIR 0.003 (0.00011) 0. 05 (0,002) ‘Standard value | Serviceable limit Front 7 Topemion | 421.68) eee, Free length | 451.7(17.78) | 425(16.79) ike 50.09 8.08 Trem Standard value Serviceable limit Rear = epenion | 210.4(8.289) | 205 (07 free length f noe Them | Sanda aloe [Serville a aime ae CL Rear fork 21.44t~21.5 baking. | @letima ta | 218 0.88) Caner 21.er~21 48 ' eh an | Gecmnty | 41a 90H 6 ELECTRICAL Trem | Standard value | Seryieeable Carbon brush | 12~31mm | 5.5mm length (0.47~0,51in) | (0.22in) Brush spring O.5~0.5ke Oke tension (.1~1.31bs) | (08h)HondaaFun rH Courtesy | 10. WIRING DIAGRAM ~ a 4508 a 3: ia mats wn erie—A Adjust ignition timing 1 — valve tappet clearnee,... 7 cam chan css d® — carburetor ane Alternator generator 88 Air cleaner 16 Fy Battery sssenisesee toe Bleeding brake system 15,73 Brakes... crease Brake caliper adjustment M4 Brake lever travel 72 Brake pedal travel 0-15 Body electrical... 87 Bed pencil te ss Bore and stroke... see Bi a neeenenene 116 —e- Cam chain tensioner 13, 46 Carburetor 57 Camshaft 24 holder 0 24 Charging system. 93 Change oil and oil filter ....18 Clutch sil Compression ratio... us ea adbacin nathan sell! — pressure 7 Condenser... 2 Connecting: rod cere Bh Contact breaker 9 Crankshaft sven Cylinder 24 — arrangement 24 tlie iisicininneniiel Cylinder head 24 pe Displacement sisal Drive chain TE Engine installation 20 Engine removal 20 | MA INDEX | Front suspension Front wheel and tire Fuel tank capacity Gear ratio 8 Gear shift drum .. Gear shift drum stopper Generator Ieling speed .. Ignition timing Ignition system Ignition coil Lubrication system —M— Main ignition switch Maintenance operation =e Neutral switch... Oil fer — element il pump Oil pressure switch .... Oil warning lamp Olt drain plog eakazags 116 aes 107 106 14,39 Courtesy HondaaFun honda. com Piston a Piston pi 7 Piston ring Rear suspension Rear fork Rear wheel Regulator Relief valve .. Rocker arm — shaft Special tools Silicone rectifier Spark advancer Spark plug Specifications Starting elutch..... Starter magnetic switeh Starting moter. — able Steering Stop switch ‘Technical data Throttle valve Trouble shooting ‘Transmiation.. Valve ‘Vacuum gauge Valve timing Wiring diagram. gebes 115 at 107 31 at 104 118